Ultrasonic surgical instrument with removable handle assembly

ABSTRACT

An apparatus comprises a body and a shaft assembly. The shaft assembly is configured to couple with the body such that the shaft assembly extends distally relative to the body. The shaft assembly comprises a tubular member, an acoustic waveguide, and a guiding member. The acoustic waveguide is operable to selectively couple with an ultrasonic transducer assembly. The tubular member is configured to insertingly receive the acoustic waveguide. The acoustic waveguide comprises a guide feature. The guiding member is configured to engage the guide feature of the acoustic waveguide and thereby orient the acoustic waveguide in relation to the tubular member.

PRIORITY

This application claims priority to U.S. Provisional Pat. App. No.62/146,644, entitled “Ultrasonic Surgical Instrument with RemovableHandle Assembly,” filed Apr. 13, 2015, the disclosure of which isincorporated by reference herein.

This application is also a continuation-in-part of U.S. patentapplication Ser. No. 14/623,812, entitled “Ultrasonic SurgicalInstrument with Removable Handle Assembly,” filed Feb. 17, 2015, thedisclosure of which is incorporated by reference herein, and whichclaims priority to in U.S. Provisional Pat. App. No. 61/946,168,entitled “Ultrasonic Surgical Instrument with Removable HandleAssembly,” filed Feb. 28, 2014, the disclosure of which is incorporatedby reference herein.

BACKGROUND

Examples of ultrasonic surgical instruments include the HARMONIC ACE®Ultrasonic Shears, the HARMONIC WAVE® Ultrasonic Shears, the HARMONICFOCUS® Ultrasonic Shears, and the HARMONIC SYNERGY® Ultrasonic Blades,all by Ethicon Endo-Surgery, Inc. of Cincinnati, Ohio. Further examplesof such devices and related concepts are disclosed in U.S. Pat. No.5,322,055, entitled “Clamp Coagulator/Cutting System for UltrasonicSurgical Instruments,” issued Jun. 21, 1994, the disclosure of which isincorporated by reference herein; U.S. Pat. No. 5,873,873, entitled“Ultrasonic Clamp Coagulator Apparatus Having Improved Clamp Mechanism,”issued Feb. 23, 1999, the disclosure of which is incorporated byreference herein; U.S. Pat. No. 5,980,510, entitled “Ultrasonic ClampCoagulator Apparatus Having Improved Clamp Arm Pivot Mount,” filed Oct.10, 1997, the disclosure of which is incorporated by reference herein;U.S. Pat. No. 6,325,811, entitled “Blades with Functional BalanceAsymmetries for use with Ultrasonic Surgical Instruments,” issued Dec.4, 2001, the disclosure of which is incorporated by reference herein;U.S. Pat. No. 6,773,444, entitled “Blades with Functional BalanceAsymmetries for Use with Ultrasonic Surgical Instruments,” issued Aug.10, 2004, the disclosure of which is incorporated by reference herein;U.S. Pat. No. 6,783,524, entitled “Robotic Surgical Tool with UltrasoundCauterizing and Cutting Instrument,” issued Aug. 31, 2004, thedisclosure of which is incorporated by reference herein; U.S. Pat. No.8,461,744, entitled “Rotating Transducer Mount for Ultrasonic SurgicalInstruments,” issued Jun. 11, 2013, the disclosure of which isincorporated by reference herein; U.S. Pat. No. 8,591,536, entitled“Ultrasonic Surgical Instrument Blades,” issued Nov. 26, 2013, thedisclosure of which is incorporated by reference herein; and U.S. Pat.No. 8,623,027, entitled “Ergonomic Surgical Instruments,” issued Jan. 7,2014, the disclosure of which is incorporated by reference herein.

Still further examples of ultrasonic surgical instruments are disclosedin U.S. Pub. No. 2006/0079874, entitled “Tissue Pad for Use with anUltrasonic Surgical Instrument,” published Apr. 13, 2006, the disclosureof which is incorporated by reference herein; U.S. Pub. No.2007/0191713, entitled “Ultrasonic Device for Cutting and Coagulating,”published Aug. 16, 2007, the disclosure of which is incorporated byreference herein; U.S. Pub. No. 2007/0282333, entitled “UltrasonicWaveguide and Blade,” published Dec. 6, 2007, the disclosure of which isincorporated by reference herein; U.S. Pub. No. 2008/0200940, entitled“Ultrasonic Device for Cutting and Coagulating,” published Aug. 21,2008, the disclosure of which is incorporated by reference herein; andU.S. Pub. No. 2010/0069940, entitled “Ultrasonic Device for FingertipControl,” published Mar. 18, 2010, the disclosure of which isincorporated by reference herein.

Some ultrasonic surgical instruments may include a cordless transducersuch as that disclosed in U.S. Pub. No. 2012/0112687, entitled “RechargeSystem for Medical Devices,” published May 10, 2012, the disclosure ofwhich is incorporated by reference herein; U.S. Pub. No. 2012/0116265,entitled “Surgical Instrument with Charging Devices,” published May 10,2012, the disclosure of which is incorporated by reference herein;and/or U.S. Pat. App. No. 61/410,603, filed Nov. 5, 2010, entitled“Energy-Based Surgical Instruments,” the disclosure of which isincorporated by reference herein.

Additionally, some ultrasonic surgical instruments may include anarticulating shaft section and/or a bendable ultrasonic waveguide.Examples of such ultrasonic surgical instruments are disclosed in U.S.Pat. No. 5,897,523, entitled “Articulating Ultrasonic SurgicalInstrument,” issued Apr. 27, 1999, the disclosure of which isincorporated by reference herein; U.S. Pat. No. 5,989,264, entitled“Ultrasonic Polyp Snare,” issued Nov. 23, 1999, the disclosure of whichis incorporated by reference herein; U.S. Pat. No. 6,063,098, entitled“Articulable Ultrasonic Surgical Apparatus,” issued May 16, 2000, thedisclosure of which is incorporated by reference herein; U.S. Pat. No.6,090,120, entitled “Articulating Ultrasonic Surgical Instrument,”issued Jul. 18, 2000, the disclosure of which is incorporated byreference herein; U.S. Pat. No. 6,454,782, entitled “Actuation Mechanismfor Surgical Instruments,” issued Sep. 24, 2002, the disclosure of whichis incorporated by reference herein; U.S. Pat. No. 6,589,200, entitled“Articulating Ultrasonic Surgical Shears,” issued Jul. 8, 2003, thedisclosure of which is incorporated by reference herein; U.S. Pat. No.6,752,815, entitled “Method and Waveguides for Changing the Direction ofLongitudinal Vibrations,” issued Jun. 22, 2004, the disclosure of whichis incorporated by reference herein; U.S. Pat. No. 7,135,030, entitled“Articulating Ultrasonic Surgical Shears,” issued Nov. 14, 2006; U.S.Pat. No. 7,621,930, entitled “Ultrasound Medical Instrument Having aMedical Ultrasonic Blade,” issued Nov. 24, 2009, the disclosure of whichis incorporated by reference herein; U.S. Pub. No. 2014/0005701,published Jan. 2, 2014, entitled “Surgical Instruments with ArticulatingShafts,” the disclosure of which is incorporated by reference herein;U.S. Pub. No. 2014/005703, entitled “Surgical Instruments withArticulating Shafts,” published Jan. 2, 2014, the disclosure of which isincorporated by reference herein; U.S. Pub. No. 2014/0114334, entitled“Flexible Harmonic Waveguides/Blades for Surgical Instruments,”published Apr. 24, 2014, the disclosure of which is incorporated byreference herein; U.S. Pub. No. 2015/0080924, entitled “ArticulationFeatures for Ultrasonic Surgical Instrument,” published Mar. 19, 2015,the disclosure of which is incorporated by reference herein; and U.S.patent application Ser. No. 14/258,179, entitled Ultrasonic SurgicalDevice with Articulating End Effector,” filed Apr. 22, 2014, thedisclosure of which is incorporated by reference herein.

While several surgical instruments and systems have been made and used,it is believed that no one prior to the inventors has made or used theinvention described in the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims which particularly pointout and distinctly claim this technology, it is believed this technologywill be better understood from the following description of certainexamples taken in conjunction with the accompanying drawings, in whichlike reference numerals identify the same elements and in which:

FIG. 1 depicts a side elevational view of an exemplary ultrasonicsurgical instrument;

FIG. 2 depicts a perspective view of the instrument of FIG. 1;

FIG. 3 depicts a perspective view of the instrument of FIG. 1, with adisposable portion separated from a reusable portion;

FIG. 4 depicts a perspective view of an end effector of the instrumentof FIG. 1, in an open configuration;

FIG. 5 depicts a partially exploded view of the end effector of FIG. 4;

FIG. 6A depicts a side elevational view of the end effector of FIG. 4,in the open configuration;

FIG. 6B depicts a side elevational view of the end effector of FIG. 4,in a closed configuration;

FIG. 7 depicts a side cross-sectional view of the end effector of FIG.4, in the open configuration;

FIG. 8 depicts a side elevational view of the reusable portion of theinstrument of FIG. 1, with a housing half removed;

FIG. 9 depicts a perspective view of the disposable portion of theinstrument of FIG. 1;

FIG. 10 depicts a perspective view of the proximal end of the disposableportion of FIG. 9;

FIG. 11 depicts a perspective view of an outer tube from a shaftassembly of the disposable portion of FIG. 9;

FIG. 12 depicts a perspective view of the proximal portion of the outertube of FIG. 11;

FIG. 13 depicts a perspective view of an inner tube from the shaftassembly of the disposable portion of FIG. 9;

FIG. 14 depicts a perspective view of the proximal portion of the innertube of FIG. 13;

FIG. 15 depicts a cross-sectional perspective view of the inner tube ofFIG. 13, taken along line 15-15 of FIG. 13;

FIG. 16 depicts an exploded view of the proximal portion of the outertube of FIG. 11, the proximal portion of the inner tube of FIG. 13, andthe proximal portion of an acoustic waveguide from the shaft assembly ofthe disposable portion of FIG. 9;

FIG. 17 depicts a partially exploded view of the components of FIG. 16,with the waveguide inserted in the inner tube;

FIG. 18 depicts a perspective view of the components of FIG. 16assembled together;

FIG. 19 depicts a proximal end of the shaft assembly of the disposableportion of FIG. 9;

FIG. 20 depicts a partially exploded view of the shaft assembly of FIG.19;

FIG. 21 depicts a side cross-sectional view of the shaft assembly ofFIG. 19;

FIG. 22 depicts a perspective view of a mode selection knob of the shaftassembly of FIG. 19;

FIG. 23 depicts another perspective view of the knob of FIG. 22;

FIG. 24 depicts a perspective view of a coupling member of the shaftassembly of FIG. 19;

FIG. 25 depicts an elevational view of the distal end of the couplingmember of FIG. 24;

FIG. 26 depicts a perspective view of a mode drive member of the shaftassembly of FIG. 19;

FIG. 27 depicts another perspective view of the mode drive member ofFIG. 26;

FIG. 28 depicts a perspective view of an inner tube grounding member ofthe shaft assembly of FIG. 19;

FIG. 29 depicts another perspective view of the grounding member of FIG.28;

FIG. 30 depicts a perspective view of a portion of the shaft assembly ofFIG. 19, showing the coupling member of FIG. 24, the mode drive memberof FIG. 26, the grounding member of FIG. 28, and the waveguide;

FIG. 31 depicts a perspective view of the components of FIG. 30, alongwith the knob of FIG. 22, a return spring, the outer tube of FIG. 11,and a flush port member;

FIG. 32 depicts a top plan view of the components of FIG. 31;

FIG. 33 depicts a cross-sectional view of the components of FIG. 31,taken along line 33-33 of FIG. 32;

FIG. 34 depicts a cross-sectional view of the components of FIG. 31,taken along line 34-34 of FIG. 32;

FIG. 35 depicts a cross-sectional view of the components of FIG. 31,taken along line 35-35 of FIG. 32;

FIG. 36A depicts a partial perspective view of the disposable portion ofFIG. 9, with the end effector in the open configuration and the modeselection knob in a non-actuated position;

FIG. 36B depicts a partial perspective view of the disposable portion ofFIG. 9, with the end effector in a cleaning mode and the mode selectionknob in an actuated position;

FIG. 37 depicts a side cross-sectional view of the end effector of FIG.4 in the cleaning mode;

FIG. 38A depicts a top plan view of the proximal portion of thedisposable portion of FIG. 9, with the mode selection knob in thenon-actuated position;

FIG. 38B depicts a top plan view of the proximal portion of thedisposable portion of FIG. 9, with the mode selection knob in theactuated position;

FIG. 39A depicts a side cross-sectional view of the proximal portion ofthe disposable portion of FIG. 9, taken along line 39-39 of FIG. 32,with the mode selection knob in the non-actuated position;

FIG. 39B depicts a side cross-sectional view of the proximal portion ofthe disposable portion of FIG. 9, taken along line 39-39 of FIG. 32,with the mode selection knob in the actuated position;

FIG. 40A depicts an enlarged side cross-sectional view of sealingfeatures in the proximal portion of the disposable portion of FIG. 9, ina regular operation mode;

FIG. 40B depicts an enlarged side cross-sectional view of the sealingfeatures of FIG. 40A, in the cleaning mode;

FIG. 41A depicts an enlarged side cross-sectional view of mode selectioncomponents in the proximal portion of the disposable portion of FIG. 9,in a regular operation mode;

FIG. 41B depicts an enlarged side cross-sectional view of the modeselection components of FIG. 41A, at a first stage during a transitionfrom the regular operation mode to the cleaning mode;

FIG. 41C depicts an enlarged side cross-sectional view of the modeselection components of FIG. 41A, at a second stage during a transitionfrom the regular operation mode to the cleaning mode;

FIG. 41D depicts an enlarged side cross-sectional view of the modeselection components of FIG. 41A, fully transitioned to the cleaningmode;

FIG. 42 depicts a partially exploded view of the proximal portion of thedisposable portion of FIG. 9, showing trigger components;

FIG. 43 depicts a partially exploded view of outer tube actuationcomponents of the disposable portion of FIG. 9;

FIG. 44A depicts a side elevational view of the proximal portion of thedisposable portion of FIG. 9, with a housing half removed, showing atrigger in a non-actuated position and a button in a non-actuatedposition;

FIG. 44B depicts a side elevational view of the components of FIG. 44A,showing the trigger in an actuated position and the button in thenon-actuated position;

FIG. 44C depicts a side elevational view of the components of FIG. 44A,showing the trigger in the actuated position and the button in anactuated position;

FIG. 45 depicts a perspective view of the reusable portion of theinstrument of FIG. 1;

FIG. 46 depicts a perspective view of the instrument of FIG. 1, with aregion of the reusable portion of FIG. 45 cut away to reveal positioningof components within the reusable portion;

FIG. 47 depicts a perspective view of the reusable portion of FIG. 45with a housing half removed;

FIG. 48 depicts a perspective view of a generator module and ultrasonictransducer assembly of the reusable portion of FIG. 45;

FIG. 49 depicts a side cross-sectional view of the components of FIG.48;

FIG. 50 depicts an exploded view of the components of FIG. 48;

FIG. 51 depicts an exploded view of torque wrench assembly associatedwith the ultrasonic transducer assembly of FIG. 48;

FIG. 52 depicts a perspective view of a pawl ring of the torque wrenchassembly of FIG. 51;

FIG. 53 depicts another perspective view of the pawl ring of FIG. 52;

FIG. 54 depicts a cross-sectional view of the pawl ring of FIG. 52,taken along line 54-54 of FIG. 55;

FIG. 55 depicts a cross-sectional view of the pawl ring of FIG. 52,taken along line 55-55 of FIG. 54;

FIG. 56 depicts a cross-sectional view of the pawl ring of FIG. 52,taken along line 56-56 of FIG. 55;

FIG. 57 depicts a perspective view of a sliding rotary drive member ofthe torque wrench assembly of FIG. 51;

FIG. 58 depicts a cross-sectional view of the drive member of FIG. 57,taken along line 58-58 of FIG. 59;

FIG. 59 depicts a cross-sectional view of the drive member of FIG. 57,taken along line 59-59 of FIG. 58;

FIG. 60A depicts a partial, side elevational view of the reusableportion of FIG. 45, with a housing half removed;

FIG. 60B depicts a partial, side elevational view of the reusableportion of FIG. 45, with a housing half removed, and with the disposableportion of FIG. 9 inserted into a recess of the reusable portion;

FIG. 60C depicts a partial, side elevational view of the reusableportion of FIG. 45, with a housing half removed, with the disposableportion of FIG. 9 inserted into the recess of the reusable portion, andwith the transducer assembly fully coupled with the waveguide;

FIG. 61A depicts a partial, side cross-sectional view of the reusableportion of FIG. 45;

FIG. 61B depicts a partial, side cross-sectional view of the reusableportion of FIG. 45, with the disposable portion of FIG. 9 inserted intoa recess of the reusable portion;

FIG. 61C depicts a partial, side cross-sectional view of the reusableportion of FIG. 45, with the disposable portion of FIG. 9 inserted intothe recess of the reusable portion, and with the transducer assemblyfully coupled with the waveguide;

FIG. 62A depicts a cross-sectional view of the assembly of FIG. 60B,taken along line 62-62 of FIG. 60B, with the drive member of FIG. 57 ina first angular position;

FIG. 62B depicts a cross-sectional view of the assembly of FIG. 60B,taken along line 62-62 of FIG. 60B, with the drive member of FIG. 57 ina second angular position;

FIG. 62C depicts a cross-sectional view of the assembly of FIG. 60B,taken along line 62-62 of FIG. 60B, with the drive member of FIG. 57 ina third angular position;

FIG. 62D depicts a cross-sectional view of the assembly of FIG. 60B,taken along line 62-62 of FIG. 60B, with the drive member of FIG. 57 ina fourth angular position;

FIG. 62E depicts a cross-sectional view of the assembly of FIG. 60B,taken along line 62-62 of FIG. 60B, with the drive member of FIG. 57 ina fifth angular position;

FIG. 62F depicts a cross-sectional view of the assembly of FIG. 60B,taken along line 62-62 of FIG. 60B, with the drive member of FIG. 57 ina sixth angular position;

FIG. 63 depicts partial side elevational view of the pawl ring of FIG.52 and the drive member of FIG. 57, with the drive member of FIG. 57 inthe fifth angular position associated with FIG. 62E;

FIG. 64 depicts a partial, side elevational view of the reusable portionof FIG. 45, with a housing half removed, with the disposable portion ofFIG. 9 inserted into a recess of the reusable portion, with thetransducer assembly fully coupled with the waveguide; and with the pawlring of FIG. 52 slid to a proximal position to enable decoupling of thewaveguide from the transducer assembly;

FIG. 65 depicts a perspective view of an exemplary alternativeultrasonic surgical instrument;

FIG. 66 depicts a perspective view of the instrument of FIG. 65, with adisposable portion separated from a reusable portion;

FIG. 67 depicts a perspective view of the disposable portion of theinstrument of FIG. 65;

FIG. 68 depicts an enlarged perspective view of a proximal portion ofthe disposable portion of FIG. 67;

FIG. 69 depicts a side elevational view of a housing half of thedisposable portion of FIG. 67;

FIG. 70 depicts a perspective view of the housing half of FIG. 69;

FIG. 71 depicts an exploded view of the disposable portion of FIG. 67;

FIG. 72 depicts a perspective view of a selective coupling assembly ofthe disposable portion of FIG. 67;

FIG. 73 depicts a side cross-sectional view of the selective couplingassembly of FIG. 72;

FIG. 74 depicts a perspective view of the reusable portion of theinstrument of FIG. 65, with a housing half removed;

FIG. 75 depicts a perspective view of a pawl ring of the reusableportion of FIG. 74;

FIG. 76 depicts a perspective view of the pawl ring of FIG. 75;

FIG. 77 depicts a perspective view of the pawl ring of FIG. 75;

FIG. 78 depicts a side elevational view of the pawl ring of FIG. 75

FIG. 79A depicts a partial perspective view of the reusable portion ofFIG. 65, with a housing half removed;

FIG. 79B depicts a partial perspective view of the reusable portion ofFIG. 65, with a housing half removed, and with the disposable portion ofFIG. 67 inserted into a recess of the reusable portion;

FIG. 79C depicts a partial perspective view of the reusable portion ofFIG. 65, with a housing half removed, with the disposable portion ofFIG. 67 inserted into the recess of the reusable portion, and with theselective coupling assembly of FIG. 72 slid to a proximal position toengage the pawl ring of FIG. 75;

FIG. 79D depicts a partial perspective view of the reusable portion ofFIG. 65, with a housing half removed, with the disposable portion ofFIG. 67 inserted into the recess of the reusable portion, and with thetransducer assembly fully coupled with the waveguide;

FIG. 80A depicts a partial, side elevational view of the reusableportion of FIG. 65, with a housing half removed;

FIG. 80B depicts a partial, side elevational view of the reusableportion of FIG. 65, with a housing half removed, and with the disposableportion of FIG. 67 inserted into a recess of the reusable portion;

FIG. 80C depicts a partial, side elevational view of the reusableportion of FIG. 65, with a housing half removed, with the disposableportion of FIG. 67 inserted into the recess of the reusable portion, andwith the selective coupling assembly of FIG. 72 slid to a proximalposition to engage the pawl ring of FIG. 75;

FIG. 80D depicts a partial, side elevational view of the reusableportion of FIG. 65, with a housing half removed, with the disposableportion of FIG. 67 inserted into the recess of the reusable portion, andwith the transducer assembly fully coupled with the waveguide;

FIG. 81 depicts a perspective view of the proximal end of an exemplaryalternative disposable portion of the instrument of FIG. 1;

FIG. 82 depicts a perspective view of the proximal end of anotherexemplary alternative disposable portion of the instrument of FIG. 1;

FIG. 83 depicts a side elevational view of an exemplary alternativeultrasonic surgical instrument;

FIG. 84 depicts a perspective view of a reusable portion of theinstrument of FIG. 83;

FIG. 85 depicts another perspective view of the reusable portion of FIG.84, with a slider exploded away from the rest of the reusable portion;

FIG. 86 depicts another perspective view of the reusable portion of FIG.84, with a housing half removed;

FIG. 87 depicts a perspective view of a pawl ring of the reusableportion of FIG. 84;

FIG. 88 depicts another perspective view of the pawl ring of FIG. 87;

FIG. 89 depicts a perspective view of a disposable portion of theinstrument of FIG. 83;

FIG. 90A depicts a side elevational view of the disposable portion ofFIG. 89, with an end effector of the disposable portion in an openconfiguration;

FIG. 90B depicts a side elevational view of the disposable portion ofFIG. 89, with the end effector in a closed configuration;

FIG. 91A depicts a side elevational view of the proximal end of thedisposable portion of FIG. 89, with a housing half removed, and with atrigger in a non-actuated position;

FIG. 91B depicts a side elevational view of the proximal end of thedisposable portion of FIG. 89, with a housing half removed, and with thetrigger in an actuated position;

FIG. 92 depicts a perspective view of an actuation yoke of thedisposable portion of FIG. 89;

FIG. 93A depicts a side elevational view of the proximal end of thedisposable portion of FIG. 89, with a housing half and the actuationyoke removed, and with the trigger in the non-actuated position;

FIG. 93B depicts a side elevational view of the proximal end of thedisposable portion of FIG. 89, with a housing half and the actuationyoke removed, and with the trigger in the actuated position;

FIG. 94 depicts a cross-sectional side view of the proximal end of shaftassembly components of the disposable portion of FIG. 89;

FIG. 95 depicts an exploded perspective view of the shaft assemblycomponents of FIG. 94;

FIG. 96 depicts an exploded perspective view of a yoke actuated assemblyof the shaft assembly components of FIG. 94;

FIG. 97 depicts a perspective view of a tube coupling member of the yokeactuated assembly of FIG. 96;

FIG. 98 depicts a cross-sectional perspective view of the couplingmember of FIG. 97, taken along line 98-98 of FIG. 97;

FIG. 99 depicts a perspective view of the proximal end of an outer tubeof the shaft assembly components of FIG. 94;

FIG. 100 depicts a cross-sectional perspective view of the proximal endof the outer tube of FIG. 99 with the coupling member of FIG. 97separated from the outer tube;

FIG. 101 depicts a cross-sectional perspective view of the proximal endof the outer tube of FIG. 99 with the coupling member of FIG. 97 coupledwith the outer tube;

FIG. 102 depicts a perspective view of an inner tube assembly of theshaft assembly components of FIG. 94;

FIG. 103 depicts a perspective view of a coupling member assembly of theinner tube assembly of FIG. 102;

FIG. 104 depicts a perspective view of a deflector member of thecoupling member assembly of FIG. 103;

FIG. 105 depicts a perspective view of a waveguide guiding member of theshaft assembly components of FIG. 94;

FIG. 106 depicts another perspective view of the waveguide guidingmember of FIG. 105;

FIG. 107 depicts another perspective view of the waveguide guidingmember of FIG. 105;

FIG. 108 depicts a perspective view of the proximal end of a waveguideof the shaft assembly components of FIG. 94;

FIG. 109 depicts a side elevational view of the disposable portion ofFIG. 89 in a cleaning mode;

FIG. 110 depicts a side elevational view of the proximal end of thedisposable portion of FIG. 89, with a housing half and the actuationyoke removed, and with the disposable portion in the cleaning mode ofFIG. 109;

FIG. 111 depicts a perspective view of the disposable portion of FIG. 89in the cleaning mode of FIG. 109;

FIG. 112 depicts another perspective view of the disposable portion ofFIG. 89 in the cleaning mode of FIG. 109;

FIG. 113 depicts a cross-sectional side view of the proximal end of theshaft assembly components of FIG. 94, with the shaft assembly componentsin the cleaning mode of FIG. 109;

FIG. 114 depicts an enlarged cross-sectional side view of a knobassembly of the shaft assembly components of FIG. 94, with the shaftassembly components in the cleaning mode of FIG. 109;

FIG. 115 depicts a perspective view of a cleaning port body of the knobassembly of FIG. 114;

FIG. 116 depicts a cross-sectional perspective view of the cleaning portbody of FIG. 115;

FIG. 117A depicts a perspective view of the waveguide of FIG. 108 at afirst stage of insertion in the waveguide guiding member of FIG. 105,with the waveguide starting at a first angular orientation;

FIG. 117B depicts a perspective view of the waveguide of FIG. 108 at asecond stage of insertion in the waveguide guiding member of FIG. 105,with the waveguide having started at the first angular orientation;

FIG. 117C depicts a perspective view of the waveguide of FIG. 108 at athird stage of insertion in the waveguide guiding member of FIG. 105,with the waveguide having started at the first angular orientation;

FIG. 117D depicts a perspective view of the waveguide of FIG. 108 at afourth stage of insertion in the waveguide guiding member of FIG. 105,with the waveguide having started at the first angular orientation;

FIG. 117E depicts a perspective view of the waveguide of FIG. 108 at afifth stage of insertion in the waveguide guiding member of FIG. 105,with the waveguide having started at the first angular orientation;

FIG. 117F depicts a perspective view of the waveguide of FIG. 108 at asixth stage of insertion in the waveguide guiding member of FIG. 105,with the waveguide having started at the first angular orientation;

FIG. 117G depicts a perspective view of the waveguide of FIG. 108 at aseventh stage of insertion in the waveguide guiding member of FIG. 105,with the waveguide having started at the first angular orientation;

FIG. 117H depicts a perspective view of the waveguide of FIG. 108 at aneighth stage of insertion in the waveguide guiding member of FIG. 105,with the waveguide having started at the first angular orientation;

FIG. 117I depicts a perspective view of the waveguide of FIG. 108 fullyinserted in the waveguide guiding member of FIG. 105, with the waveguidehaving started at the first angular orientation;

FIG. 118A depicts a perspective view of the waveguide of FIG. 108 at afirst stage of insertion in the waveguide guiding member of FIG. 105,with the waveguide starting at a second angular orientation;

FIG. 118B depicts a perspective view of the waveguide of FIG. 108 at asecond stage of insertion in the waveguide guiding member of FIG. 105,with the waveguide having started at the second angular orientation;

FIG. 118C depicts a perspective view of the waveguide of FIG. 108 at athird stage of insertion in the waveguide guiding member of FIG. 105,with the waveguide having started at the second angular orientation;

FIG. 118D depicts a perspective view of the waveguide of FIG. 108 at afourth stage of insertion in the waveguide guiding member of FIG. 105,with the waveguide having started at the second angular orientation;

FIG. 118E depicts a perspective view of the waveguide of FIG. 108 at afifth stage of insertion in the waveguide guiding member of FIG. 105,with the waveguide having started at the second angular orientation; and

FIG. 118F depicts a perspective view of the waveguide of FIG. 108 fullyinserted in the waveguide guiding member of FIG. 105, with the waveguidehaving started at the second angular orientation.

The drawings are not intended to be limiting in any way, and it iscontemplated that various embodiments of the technology may be carriedout in a variety of other ways, including those not necessarily depictedin the drawings. The accompanying drawings incorporated in and forming apart of the specification illustrate several aspects of the presenttechnology, and together with the description serve to explain theprinciples of the technology; it being understood, however, that thistechnology is not limited to the precise arrangements shown.

DETAILED DESCRIPTION

The following description of certain examples of the technology shouldnot be used to limit its scope. Other examples, features, aspects,embodiments, and advantages of the technology will become apparent tothose skilled in the art from the following description, which is by wayof illustration, one of the best modes contemplated for carrying out thetechnology. As will be realized, the technology described herein iscapable of other different and obvious aspects, all without departingfrom the technology. Accordingly, the drawings and descriptions shouldbe regarded as illustrative in nature and not restrictive.

It is further understood that any one or more of the teachings,expressions, embodiments, examples, etc. described herein may becombined with any one or more of the other teachings, expressions,embodiments, examples, etc. that are described herein. Thefollowing-described teachings, expressions, embodiments, examples, etc.should therefore not be viewed in isolation relative to each other.Various suitable ways in which the teachings herein may be combined willbe readily apparent to those of ordinary skill in the art in view of theteachings herein. Such modifications and variations are intended to beincluded within the scope of the claims.

For clarity of disclosure, the terms “proximal” and “distal” are definedherein relative to a human or robotic operator of the surgicalinstrument. The term “proximal” refers the position of an element closerto the human or robotic operator of the surgical instrument and furtheraway from the surgical end effector of the surgical instrument. The term“distal” refers to the position of an element closer to the surgical endeffector of the surgical instrument and further away from the human orrobotic operator of the surgical instrument.

I. Overview of Exemplary Ultrasonic Surgical Instrument

FIGS. 1-3 show an exemplary ultrasonic surgical instrument (10) that isconfigured to be used in minimally invasive surgical procedures (e.g.,via a trocar or other small diameter access port, etc.). As will bedescribed in greater detail below, instrument (10) is operable to cuttissue and seal or weld tissue (e.g., a blood vessel, etc.)substantially simultaneously. Instrument (10) of this example comprisesa disposable assembly (100) and a reusable assembly (200). The distalportion of reusable assembly (200) is configured to removably receivethe proximal portion of disposable assembly (100), as seen in FIGS. 2-3,to form instrument (10).

In an exemplary use, assemblies (100, 200) are coupled together to forminstrument (10) before a surgical procedure, the assembled instrument(10) is used to perform the surgical procedure, and then assemblies(100, 200) are decoupled from each other for further processing. In someinstances, after the surgical procedure is complete, disposable assembly(100) is immediately disposed of while reusable assembly (200) issterilized and otherwise processed for re-use. By way of example only,reusable assembly (200) may be sterilized in a conventional relativelylow temperature, relatively low pressure, hydrogen peroxidesterilization process. Alternatively, reusable assembly (200) may besterilized using any other suitable systems and techniques (e.g.,autoclave, etc.). In some versions, reusable assembly (200) may besterilized and reused approximately 100 times. Alternatively, reusableassembly (200) may be subject to any other suitable life cycle. Forinstance, reusable assembly (200) may be disposed of after a single use,if desired. While disposable assembly (100) is referred to herein asbeing “disposable,” it should be understood that, in some instances,disposable assembly (100) may also be sterilized and otherwise processedfor re-use. By way of example only, disposable assembly (100) may besterilized and reused approximately 2-30 times, using any suitablesystems and techniques. Alternatively, disposable assembly (100) may besubject to any other suitable life cycle.

In some versions, disposable assembly (100) and/or reusable assembly(200) includes one or more features that are operable to track usage ofthe corresponding assembly (100, 200), and selectively restrictoperability of the corresponding assembly (100, 200) based on use. Forinstance, disposable assembly (100) and/or reusable assembly (200) mayinclude one or more counting sensors and a control logic (e.g.,microprocessor, etc.) that is in communication with the countingsensor(s). The counting sensor(s) may be able to detect the number oftimes the ultrasonic transducer of instrument (10) is activated, thenumber of surgical procedures the corresponding assembly (100, 200) isused in, the number of trigger closures, and/or any other suitableconditions associated with use. The control logic may track data fromthe counting sensor(s) and compare the data to one or more thresholdvalues. When the control logic determines that one or more thresholdvalues have been exceeded, the control logic may execute a controlalgorithm to disable operability of one or more components in thecorresponding assembly (100, 200). In instances where the control logicstores two or more threshold values (e.g., a first threshold for numberof activations and a second threshold for number of surgical procedures,etc.), the control logic may disable operability of one or morecomponents in the corresponding assembly (100, 200) the first time oneof those thresholds is exceeded, or on some other basis.

In versions where a control logic is operable to disable instrument (10)based on the amount of use, the control logic may also determine whetherinstrument (10) is currently being used in a surgical procedure, andrefrain from disabling instrument (10) until that particular surgicalprocedure is complete. In other words, the control logic may allow theoperator to complete the current surgical procedure but preventinstrument (10) from being used in a subsequent surgical procedure.Various suitable forms that counters or other sensors may take will beapparent to those of ordinary skill in the art in view of the teachingsherein. Various suitable forms that a control logic may take will alsobe apparent to those of ordinary skill in the art in view of theteachings herein. Similarly, various suitable control algorithms thatmay be used to restrict usage of instrument (10) will be apparent tothose of ordinary skill in the art in view of the teachings herein. Ofcourse, some versions of instrument (10) may simply omit features thattrack and/or restrict the amount of usage of instrument (10).

Disposable assembly (100) of the present example comprises a bodyportion (110), a shaft assembly (150) extending distally from bodyportion (110), and an end effector (180) located at the distal end ofshaft assembly (150). As best seen in FIGS. 4-7, end effector (180) ofthis example comprises a clamp arm (182) and an ultrasonic blade (190).Clamp arm (182) includes a clamp pad (184), which faces blade (190). Asshown in FIGS. 6A-6B and as will be described in greater detail below,clamp arm (182) is pivotable toward and away from blade (190) toselectively compress tissue between clamp pad (184) and blade (190). Asseen in FIG. 7, blade (190) is an integral feature of the distal end ofan acoustic waveguide (192), which extends coaxially through tubes (152,170), and which is configured to communicate ultrasonic vibrations toblade (190) as will be described in greater detail below.

Shaft assembly (150) comprises an outer tube (152) and an inner tube(170). Outer tube (152) is operable to translate longitudinally relativeto inner tube (170) to selectively pivot clamp arm (182) toward and awayfrom blade (190). To accomplish this, and as best seen in FIGS. 5 and 7,integral pin features (186) of clamp arm (182) pivotally secure a firstportion of clamp arm (182) to a distally projecting tongue (154) ofouter tube (152); while an inserted pin (188) pivotally secures a secondportion of clamp arm (182) to a distally projecting tongue (172) ofinner tube (170). Thus, as can be seen in the transition from FIG. 6A toFIG. 6B, tubes (152, 170) cooperate to pivot clamp arm (182) towardblade (190) when outer tube (152) is retracted proximally relative toinner tube (170). It should be understood that clamp arm (182) may bepivoted back away from blade (190) (e.g., from the position shown inFIG. 6B to the position shown in FIG. 6A) by translating outer tube(152) distally relative to inner tube (170), in reverse of the operationshown in FIGS. 6A-6B. In an exemplary use, clamp arm (182) may bepivoted toward blade (190) to grasp, compress, seal, and sever tissuecaptured between clamp pad (184) and blade (190). Clamp arm (182) may bepivoted away from blade (190) to release tissue from between clamp pad(184) and blade (190); and/or to perform blunt dissection of tissueengaging opposing outer surfaces of clamp arm (182) and blade (190).

As seen in FIG. 8, reusable assembly (200) comprises a handle housing(202). While FIG. 8 only shows one housing (202), FIGS. 2-3 show how apair of complementary housings (202) are joined together. Housing (202)defines a pistol grip (204), an upper window (206), and a distal recess(208). While reusable assembly (200) includes a pistol grip (204) inthis example, it should be understood that any other suitable kind ofgrip may be used. Housing (202) of the present example also includesseveral integral bosses (210, 212, 214, 216) that provide support foradditional components as will be described in greater detail below, suchthat housing (202) serves as a chassis for components contained withinhousing (202). As also shown in FIG. 8, reusable assembly (200) includesa battery (205), a generator (230), an ultrasonic transducer assembly(240), and a torque wrench assembly (260). As will be described ingreater detail below, battery (205) is operable to provide electricalpower to generator (230); generator (230) is operable to provideelectrical power to ultrasonic transducer assembly (240); ultrasonictransducer assembly is operable to convert electrical power intoultrasonic vibrations; and torque wrench assembly (260) is operable tomechanically and acoustically couple waveguide (192) with ultrasonictransducer assembly (240).

When waveguide (192) is sufficiently coupled with transducer assembly(240), ultrasonic vibrations that are generated by transducer assembly(240) are communicated along waveguide (192) to reach blade (190). Inthe present example, the distal end of blade (190) is located at aposition corresponding to an anti-node associated with resonantultrasonic vibrations communicated through waveguide (192), in order totune the acoustic assembly to a preferred resonant frequency f_(o) whenthe acoustic assembly is not loaded by tissue. When transducer assembly(240) is energized, the distal end of blade (190) is configured to movelongitudinally in the range of, for example, approximately 10 to 500microns peak-to-peak, and in some instances in the range of about 20 toabout 200 microns at a predetermined vibratory frequency f_(o) of, forexample, 55.5 kHz. When transducer assembly (240) of the present exampleis activated, these mechanical oscillations are transmitted throughwaveguide (192) to reach blade (190), thereby providing oscillation ofblade (190) at the resonant ultrasonic frequency. Thus, when tissue issecured between blade (190) and clamp pad (184), the ultrasonicoscillation of blade (190) may simultaneously sever the tissue anddenature the proteins in adjacent tissue cells, thereby providing acoagulative effect with relatively little thermal spread. In someversions, an electrical current may also be provided through blade (190)and/or clamp pad (184) to also seal the tissue.

Further exemplary features and operabilities for disposable assembly(100) and reusable assembly (200) will be described in greater detailbelow, while other variations will be apparent to those of ordinaryskill in the art in view of the teachings herein.

II. Disposable Assembly of Exemplary Ultrasonic Surgical Instrument

FIGS. 9-10 show disposable assembly (100) in greater detail. As notedabove, disposable assembly (100) of the present example comprises bodyportion (110), shaft assembly (150), and end effector (180). As shown inFIG. 10, body portion (110) comprises a pair of housing halves (112,114), a trigger (120), and a button (126). Trigger (120) includes anintegral tab (122) that protrudes proximally from housing halves (112,114), as will be described in greater detail below. Similarly, theproximal end of an arm (128) associated with button (126) protrudesproximally from housing halves (112, 114), as will also be described ingreater detail below. As also shown in FIGS. 9-10. Further exemplaryfeatures and operabilities for disposable assembly (100) will bedescribed in greater detail below, while other variations will beapparent to those of ordinary skill in the art in view of the teachingsherein.

A. Shaft Assembly of Disposable Assembly

FIGS. 11-30 show various components of shaft assembly (150) in greaterdetail. As noted above, shaft assembly (150) of the present examplecomprises outer tube (152), inner tube (170), and waveguide (192).Referring back to FIGS. 9-10, a knob (156) is secured to outer tube(152) and is thereby operable to rotate the entire shaft assembly (150)relative to body (110) as will be described in greater detail below. Asshown in FIGS. 11-12, the proximal end of outer tube (152) includes anintegral flange (158) and a ring (160) that is spaced distally fromflange (158). Ring (160) is fixedly secured to outer tube (152). Theproximal end of outer tube (152) also includes an annular indentation(161), a distal side opening (162), a pair of lateral side openings(164), upper and lower side openings (166), and a pin side opening(168).

As shown in FIGS. 13-15, inner tube (170) includes an oblique flat(174), a flush side opening (176), and a pin side opening (178). Innertube (170) further includes a pair of proximally projecting resilientarms (181). Each arm (181) defines a respective pin opening (183). Thefree end (185) of each arm (181) is flared outwardly. Arms (181) areresiliently biased to assume the positions shown in FIGS. 13-15, yetarms (181) are configured to flex outwardly as will be described ingreater detail below. As best seen in FIG. 14, inner tube (170) alsoincludes an annular indentation (171).

As shown in FIG. 16, the proximal end of waveguide (192) includes a pin(194) disposed transversely through waveguide (192). Pin (194) islocated at a longitudinal position corresponding to a node associatedwith ultrasonic vibrations that are communicated through waveguide (192)when ultrasonic transducer assembly (240) is activated. As best seen inFIGS. 41A-41D, pin is secured in waveguide (192) via a pair of e-clips(197). E-clips (197) are configured to ensure that pin (194) is centeredwithin the corresponding transverse bore formed through waveguide (192),to secure and support pin (194) in that bore, and to provide acousticisolation between waveguide (192) and pin (194). Of course, any othersuitable structures or features may be used in addition to or in lieu ofe-clips (197). A threaded stud (196) extends proximally and unitarilyfrom waveguide (192). As will be described in greater detail below, stud(196) is configured to provide a mechanical and acoustic couplingbetween waveguide (192) and ultrasonic transducer assembly (240).

FIGS. 16-18 depict the coaxial arrangement of outer tube (152), innertube (170), and waveguide (192). As shown in FIG. 17, pin (194) isreceived in pin openings (183) of resilient arms (181). Pin (194) thusmechanically couples waveguide (192) with inner tube (170), such thatinner tube (170) and waveguide (192) rotate unitarily with each other,and such that inner tube (170) and waveguide (192) do not translaterelative to each other, when pin (194) is disposed in pin openings(183). While waveguide (192) is mechanically coupled with inner tube(170), waveguide (192) is not acoustically coupled with inner tube (170)in this example. In particular, as noted above, pin (194) is located ata longitudinal position corresponding to a node associated withultrasonic vibrations that are communicated through waveguide (192).Moreover, resilient arms (181) are configured such that resilient arms(181) do not contact waveguide (192), even when pin (194) is disposed inpin openings (183). In some versions, a plurality of annular sealingmembers (e.g., o-rings, etc.) are positioned at other nodal positionsalong the length of waveguide (192). Such annular sealing members mayprovide additional points of contact between waveguide (192) and innertube (170), yet such annular sealing members would not transmit acousticvibrations from waveguide (192) to inner tube (170) since such annularsealing members would be located at longitudinal positions correspondingto nodes associated with ultrasonic vibrations that are communicatedthrough waveguide (192). Other suitable structures and relationshipsbetween waveguide (192) and inner tube (170) will be apparent to thoseof ordinary skill in the art in view of the teachings herein.

As shown in FIG. 18, when waveguide (192) and inner tube (170) are fullyinserted in outer tube (152), resilient arms (181) are positioned tocorrespond with upper and lower side openings (166). As will bedescribed in greater detail below with reference to FIGS. 41A-41D, upperand lower side openings (166) provide clearance for resilient arms (181)to flex outwardly to release pin (194) when shaft assembly (150) istransitioned to a cleaning mode. Also in the present example, pin sideopening (178) of inner tube (170) aligns with pin side opening (168) ofouter tube (152) when inner tube (170) is fully inserted in outer tube(152). This allows inner tube (170) to be coupled with outer tube (152)via a pin (not shown). Due to this coupling, inner tube (170) and outertube (152) rotate together unitarily. As noted above, inner tube (170)also rotates unitarily with waveguide (192) due to the coupling providedby pin (194). It should therefore be understood that outer tube (152),inner tube (170) and waveguide (192) all rotate together unitarily. Itshould also be noted that pin side opening (168) of outer tube (152) iselongate, extending longitudinally. This elongate, longitudinalconfiguration allows outer tube (152) to translate longitudinallyrelative to inner tube (170), even with a pin disposed in openings (168,178).

As shown in FIGS. 19-21, a mode selection knob (130) is positioned atthe proximal end of shaft assembly (150). As best seen in FIGS. 22-23,mode selection knob (130) includes a proximal flange (132), a distalflange (134), an inner shoulder (136), and a distal edge (138).Referring back to FIGS. 19-21, a coil spring (131) is coaxiallypositioned about mode selection knob (130). Coil spring (131) islongitudinally interposed between housing halves (112, 114) and proximalflange (132). Coil spring (131) thereby biases mode selection knob (130)proximally. Distal flange (134) is captured within assembled housinghalves (112, 114) and thereby provides retention preventing modeselection knob (130) from disengaging housing halves (112, 114) underthe resilient bias of coil spring (131).

As also shown in FIGS. 20-21, a coupling member (140) is coupled withmode selection knob (130). As best seen in FIGS. 24-25, coupling member(140) includes an outer flange (142), a set of longitudinally extendingsnapping arms (144), an inner flange (146), and a set of openings (148)formed through inner flange (146). Referring back to FIGS. 20-21,coupling member (140) is coupled with mode selection knob (130) suchthat inner shoulder (136) of mode selection knob (130) is capturedbetween outer flange (142) and snapping arms (144). Coupling member(140) is thus secured to mode selection knob (130) in a snap fitting.

As also shown in FIGS. 20-21, a mode drive member (141) is coupled withcoupling member (140). As best seen in FIGS. 26-27, mode drive member(141) comprises a set of proximally extending fingers (143), a pair ofoutwardly extending upper and lower tabs (145), a pair of outwardlyextending lateral tabs (147), and a pair of elongate longitudinal slots(149) proximal to lateral tabs (147). Fingers (143) are disposed withinopenings (148) of inner flange (146) in coupling member (140), with theproximal end of mode drive member (141) contacting the distal face ofinner flange (146). In some versions, fingers (143) are secured withinopenings (148) through an interference fitting. Upper and lower tabs(145) are positioned to correspond with resilient arms (181) as will bedescribed in greater detail below. Lateral tabs (147) are positioned toextend through lateral side openings (164) of outer tube (152).Referring back to FIGS. 11-12, lateral side openings (164) are bothelongate, extending longitudinally. This elongate, longitudinalconfiguration allows mode drive member (141) to translate longitudinallyrelative to outer tube (152), even with lateral tabs (147) disposed inlateral side openings (164). The positioning of lateral tabs (147) inlateral side openings (164) nevertheless provides unitary rotation ofmode drive member (141) with outer tube (152).

As also shown in FIGS. 20-21, an inner tube grounding member (173) isdisposed within inner tube (170). As best seen in FIGS. 28-29, groundingmember (173) includes a pair of longitudinally extending slots (175), apair of outwardly extending lateral tabs (177), and a pin side opening(179). As best seen in FIG. 30, slots (175) are configured to receivepin (194) of waveguide (192). The elongate, longitudinal configurationof slots (175) allows pin (194) and, hence, waveguide (192), totranslate longitudinally relative to grounding member (173) and innertube (170); yet also provides unitary rotation of pin (194) andwaveguide (192) with grounding member (173) and inner tube (170). Asalso best seen in FIG. 30, lateral tabs (177) of grounding member (173)are slidably disposed in elongate longitudinal slots (149) of mode drivemember (141). The longitudinal configuration of slots (149) allowslateral grounding member (173) and inner tube (170) to translatelongitudinally relative to mode drive member (141); yet also providesunitary rotation of lateral grounding member (173) with mode drivemember (141). Pin side opening (179) of grounding member (173) ispositioned to align with pin side opening (178) of inner tube (170) whengrounding member (173) is fully inserted within inner tube (170). Asnoted above, a pin (not shown) is disposed in pin side opening (178),coupling inner tube (170) with outer tube (152). This same pin isfurther disposed in pin side opening (179) of grounding member (173).This pin thereby provides unitary fixation of inner tube (170) withgrounding member (173); and unitary rotation of grounding member (173)with inner tube (170).

As best seen in FIG. 21, coil spring (133) is coaxially disposed aboutthe proximal end of waveguide (192). Coil spring (133) is positionedbetween a proximally facing shoulder (135) formed in the proximal end ofgrounding member (173) and the distal face of the inner flange (146) ofcoupling member (140). Coil spring (133) thus biases coupling member(140) and mode drive member (141) proximally relative to groundingmember (173). It should be understood that coil spring (133) may provideassistance to coil spring (131) described above. In addition, coilspring (133) allows coupling member (140) to float axially (i.e., suchthat coil spring (133) does not have an axial force bias. This may inturn decrease the torque required by the operator to rotate shaftassembly (150) during a surgical procedure.

Various exemplary functions and operabilities that may be provided bythe components of shaft assembly (150) described above will be describedin greater detail below. Other functions and operabilities that may beprovided by the components of shaft assembly (150) described above willbe apparent to those of ordinary skill in the art in view of theteachings herein. Similarly, other features, components, andconfigurations that may be incorporated into shaft assembly (150) willbe apparent to those of ordinary skill in the art in view of theteachings herein.

B. Cleaning Features of Disposable Assembly

Those of ordinary skill in the art will appreciate that one or morecomponents of shaft assembly (150) may experience a buildup of surgicaldebris when instrument (10) is used in a surgical procedure. By way ofexample only, one or more components of shaft assembly (150) mayexperience a buildup of coagulated blood, tissue particles, and/or otherkinds of surgical debris. Thus, in some instances, it may be desirableto clean one or more components of shaft assembly (150). By way ofexample only, after instrument (10) has been used in a surgicalprocedure, it may be desirable to clean one or more components of shaftassembly (150) before shaft assembly (150) is used in another surgicalprocedure. In addition or in the alternative, it may be desirable toclean one or more components of shaft assembly (150) in the middle of asurgical procedure. For instance, instrument (10) may be used during afirst portion of a surgical procedure, then one or more components ofshaft assembly (150) may be cleaned during a pause in the surgicalprocedure, and then instrument (10) may again be used in a secondportion of the same surgical procedure (e.g., on the same day as thefirst portion of the same surgical procedure and immediately subsequentto the first portion of the same surgical procedure). The belowdescription relates to various features and techniques that may beemployed to clean one or more components of shaft assembly (150) at thecompletion of or during a surgical procedure.

As best seen in FIGS. 31-35, a cleaning port body (151) is disposedabout the exterior of inner tube (170). Cleaning port body (151)includes a first port (153) and a second port (155), both of whichextend transversely relative to inner tube (170), through distal sideopening of outer tube (152). As best seen in FIGS. 33 and 35, first port(153) is in fluid communication with the gap between the inner diameterof inner tube (170) and the outer diameter of waveguide (192). As bestseen in FIGS. 34-35, second port (155) is in fluid communication withthe gap between the inner diameter of outer tube (152) and the outerdiameter of inner tube (170). As also seen in FIGS. 34-35, oblique flat(174) of inner tube (170) directs fluid from second port to the gapbetween the inner diameter of outer tube (152) and the outer diameter ofinner tube (170). It should be understood that ports (153, 155) are influid isolation relative to each other, such that second port (155) doesnot have a path for fluid communication with the gap between the innerdiameter of inner tube (170) and the outer diameter of waveguide (192);and such that first port (153) does not have a path for fluidcommunication with the gap between the inner diameter of outer tube(152) and the outer diameter of inner tube (170).

Each port (153, 155) is configured to couple with a corresponding sourceof cleaning fluid. For instance, each port (153, 155) may receive arespective flexible tube to provide a fluid path between port (153, 155)and the corresponding source of cleaning fluid. In addition or in thealternative, each port (153, 155) may receive a nipple, fittingassociated with syringes, or other feature of a cleaning fluid injectingdevice. Other suitable ways in which ports (153, 155) may be coupledwith respective sources of cleaning fluid will be apparent to those ofordinary skill in the art in view of the teachings herein.

Referring back to FIGS. 19-21, knob (156) of the present exampleincludes a sliding shield (157) that is operable to selectively coverand uncover ports (153, 155) as will be described in greater detailbelow. Shield (157) includes a pair of integral, proximally extendingarms (159). The proximal ends of arms (159) are secured to lateral tabs(147) of mode drive member (141). Thus, when mode drive member (141)translates longitudinally relative to other portions of shaft assembly,arms (159) and shield (157) translate with mode drive member (141).

As shown in FIGS. 36A-41D, disposable assembly (100) is configured totransition between an operational mode (FIGS. 36A, 38A, 39A, 40A, and41A) and a cleaning mode (FIGS. 36B, 37, 38B, 39B, 40B, and 41D). Thisis accomplished by driving mode selection knob (130) distally relativeto housing halves (112, 114). It should therefore be understood that, inthe present example, disposable assembly (100) will only transition fromthe operational mode to the cleaning mode when disposable assembly (100)is decoupled from reusable assembly (200). In some other versions,disposable assembly (100) may transition from an operational mode to acleaning mode when disposable assembly (100) is coupled with reusableassembly (200). As seen in FIGS. 36B, 37, 38B, 39B, 40B, and 41D, clamparm (182) pivots to a hyperextended position and blade (190) advances toa distal position when disposable assembly (100) is placed in thecleaning mode. In addition, shield (157) slides distally to reveal ports(153, 155) when disposable assembly (100) is placed in the cleaningmode.

As best seen in FIGS. 38A-38B, when mode selection knob (130) is drivendistally to place disposable assembly (100) in the cleaning mode, alatch (116) of housing half (114) engages proximal flange (132) of modeselection knob (130), thereby holding mode selection knob (130) in thedistal, cleaning mode position. Latch (116) is resiliently biased toassume the position shown in FIGS. 38A-38B. In the present example,reusable assembly (200) includes a feature that drives latch (116)laterally outwardly when disposable assembly (100) is inserted in distalrecess (208) of reusable portion (200). This laterally outwarddeflection of latch (116) causes latch (116) to release proximal flange(132) of mode selection knob (130). When this occurs, coil spring (131)drives mode selection knob (130) and associated components proximally,thereby transitioning disposable assembly (100) back to the operationalmode. Thus, the act of coupling disposable assembly (100) with reusableassembly (200) may automatically transition disposable assembly (100)from the cleaning mode to the operational mode. Alternatively, theoperator may manually deflect latch (116) laterally outwardly to releaseproximal flange (132) of mode selection knob (130), therebytransitioning disposable assembly (100) from the cleaning mode to theoperational mode.

Shaft assembly (150) includes various sealing features whose sealingstates change when disposable assembly (100) is transitioned between thecleaning mode and the operational mode. In particular, one sealingfeature includes a distal seal (193), which is coaxially interposedbetween the outer diameter of waveguide (192) and the inner diameter ofinner tube (170). In the present example, distal seal (193) comprises anelastomeric material (e.g., rubber, silicone, etc.). Distal seal (193)is located at a position corresponding to a node associated withultrasonic vibrations that are communicated through waveguide (192). Asshown in FIG. 7, when disposable assembly (100) is in normal operatingmode, distal seal (193) is positioned to prevent proximal egress offluid through the gap defined between the outer diameter of waveguide(192) and the inner diameter of inner tube (170). As shown in FIG. 37,when disposable assembly (100) is in cleaning mode, distal seal (193) ispositioned past a distal edge of inner tube (170), such that distal seal(193) permits cleaning fluid to be communicated distally through the gapdefined between the outer diameter of waveguide (192) and the innerdiameter of inner tube (170), with the cleaning fluid ultimately exitingat the distal end of inner tube (170). Thus, when disposable assembly(100) is in cleaning mode, an operator may communicate cleaning fluidthrough port (153), and such cleaning fluid may advance distally andflush out coagulated blood and/or other surgical debris that may havebuilt up in the gap defined between the outer diameter of waveguide(192) and the inner diameter of inner tube (170).

FIGS. 40A-40B show additional sealing features whose sealing stateschange when disposable assembly (100) is transitioned between thecleaning mode and the operational mode. In particular, a proximal seal(195) is interposed between the inner diameter of outer tube (152) andthe outer diameter of inner tube (170). In the present example, proximalseal (195) comprises an elastomeric material (e.g., rubber, silicone,etc.). Proximal seal (195) is secured to the inner diameter of outertube (152), such that proximal seal (195) translates longitudinally withouter tube (152) relative to inner tube (170). As shown in FIG. 40A,proximal seal (195) seals against the outer diameter of inner tube (170)when disposable assembly (100) is in an operational state. As notedabove, instrument (10) may be used in minimally invasive surgicalprocedures. In some such procedures, instruments are introduced into apatient's abdominal cavity via trocars, and the patient's abdominalcavity is insufflated with pressurized air to improve visualization ofand access to organs, etc., within the abdominal cavity. With proximalseal (195) sealing against the outer diameter of inner tube (170) whendisposable assembly (100) is in an operational state, and with shaftassembly (150) inserted through a trocar to introduce end effector (180)into a patient's insufflated abdominal cavity, proximal seal (195) mayprevent the escape of pressurized air through the gap defined betweenthe inner diameter of outer tube (152) and the outer diameter of innertube (170). Similarly, distal seal (193) may prevent the escape ofpressurized air through the gap defined between the outer diameter ofwaveguide (192) and the inner diameter of inner tube (170).

When disposable assembly (100) is transitioned to the cleaning mode, asshown in FIG. 40B, proximal seal (195) is positioned in the regioncorresponding to annular indentation (171) in inner tube (170). Annularindentation (171) provides a gap permitting the communication ofcleaning fluid distally through the gap defined between the innerdiameter of outer tube (152) and the outer diameter of inner tube (170).As also shown in FIGS. 40A-40B, the distal end of port body (151)includes an annular flange (163) that selectively engages annularindentation (161) of outer tube (152). During the normal operationalmode as shown in FIG. 40A, annular flange (163) is disengaged fromannular indentation (161). However, during the cleaning mode as shown inFIG. 40B, annular flange (163) engages annular indentation (161),thereby providing a fluid seal. This prevents cleaning fluid fromescaping proximally when cleaning fluid is communicated to the gapdefined between the inner diameter of outer tube (152) and the outerdiameter of inner tube (170). It should be understood from the foregoingthat, when disposable assembly (100) is in the cleaning mode, anoperator may communicate cleaning fluid through port (155), and suchcleaning fluid may advance distally and flush out coagulated bloodand/or other surgical debris that may have built up in the gap definedbetween the inner diameter of outer tube (152) and the outer diameter ofinner tube (170).

FIGS. 41A-41D show the interactions between various components of shaftassembly (150) during the transition from the normal operating mode tothe cleaning mode. In particular, FIG. 41A shows shaft assembly (150) inthe normal operating mode. As shown, waveguide (192) is coupled withinner tube (170) via pin (194) and resilient arms (181). FIG. 41B showsmode selection knob (130) at a first state of distal advancement. Asnoted above, mode selection knob (130) is coupled with mode drive member(141) via coupling member (140). Thus, distal advancement of modeselection knob (130) to a first state of distal advancement has alsodriven mode drive member (141) to a first state of distal advancement.At this state, upper and lower tabs (145) have engaged the outwardlyflared free ends (185) of resilient arms (181) of inner tube (170). Inparticular, upper and lower tabs (145) have deflected ends (185) of arms(181) outwardly, to a point where arms (181) have disengaged pin (194)of waveguide (192). As also shown in FIG. 41B, upper and lower sideopenings (166) of outer tube (152) provide clearance for arms (181) toflex outwardly to release pin (194).

As the operator continues to advance mode selection knob (130) distally,upper and lower tabs (145) of mode drive member (141) engage pin (194)and thereby drive waveguide (192) distally as shown in FIG. 41C. Theresilience of arms (181) drives arms (181) back inwardly once upper andlower tabs (145) clear ends (185) of arms (181). During the range oftravel from the state shown in FIG. 41B to the state shown in FIG. 41C,waveguide (192) translates distally relative to inner tube (170) butouter tube (152) does not translate distally relative to inner tube(170). However, upon reaching the state shown in FIG. 41C, distal edge(138) of mode selection knob (130) engages flange (158) of outer tube(152). Thus, as the operator continues to advance mode selection knob(130) distally from the state shown in FIG. 41C to the state shown inFIG. 41D, mode selection knob (130) drives outer tube (152) distallyrelative to inner tube (170). This distal movement of outer tube (152)relative to inner tube (170) drives clamp arm (182) from the openposition shown in FIGS. 6A and 7 to the hyperextended position shown inFIGS. 36B and 37. Having clamp arm (182) in a hyperextended position mayfacilitate access to blade (190) and an adjacent region of waveguide(192), thereby facilitating the cleaning of blade (190) and the adjacentregion of waveguide (192). It should also be understood that blade (190)has transitioned from a proximal position as shown in FIGS. 6A-7 to adistal position as shown in FIGS. 36B and 37; and that this distalpositioning of blade (190) may also facilitate access to blade (190) andan adjacent region of waveguide (192), thereby facilitating the cleaningof blade (190) and the adjacent region of waveguide (192).

In some variations, inner tube (170) includes a plurality of annularindentations along its length. Such indentations may be similar toindentation (171). As noted above, a plurality of annular sealingmembers (e.g., o-rings, etc.) may be positioned at nodal positions alongthe length of waveguide (192). The annular indentations that are spacedalong the length of inner tube (170) may correspond to these annularsealing members that are spaced along the length of waveguide (192). Inother words, when disposable assembly (100) is in a normal operatingmode, annular indentations of inner tube (170) may encompass the annularsealing members along the length of waveguide (192). In some instances,the sealing members of the waveguide (192) may contact inner tube (170)at the annular indentations. As another merely illustrative alternative,there may be a nominal radial clearance (e.g., approximately 0.002inches, etc.) between the outer diameter of the sealing members and theinner diameter of the annular indentations. In either case, whendisposable assembly (100) is transitioned to the cleaning mode, thedistal advancement of waveguide (192) relative to inner tube (170) maycause the sealing members to be substantially spaced from the annularindentations, such that the resulting gaps provide a substantially clearpath for cleaning fluid to be flushed distally from port (153) throughthe space between the outer diameter of waveguide (192) and the innerdiameter of inner tube (170).

C. Triggering Features of Disposable Assembly

As noted above, body portion (110) of disposable assembly (100)comprises a trigger (120) and a button (126). As shown in FIG. 42,button (126) is pivotally secured to an integral post (115) of housinghalf (114), such that button (126) is operable to pivot about post(115). Button (126) includes a cross-bar (127), which is received in aslot (129) of arm (128). Arm (128) is slidably positioned in housinghalf (114) and is guided therein by integral bosses (117) of housinghalf (114). As button (126) is pressed to pivot button from anon-actuated position (FIG. 44A) to an actuated position (FIG. 44C),cross-bar (127) drives arm (128) proximally. The proximal movement ofthe proximal end of arm (128) is detected in reusable assembly (200) andthereby activates blade (190) as will be described in greater detailbelow.

As also shown in FIG. 42, trigger (120) is pivotally secured betweenhousing halves (112, 114) via integral pins (121), such that trigger(120) is operable to pivot about pins (121). Trigger (120) is furthercoupled with a yoke (123). In particular, integral posts (124) arereceived in corresponding slots (125) of yoke (123). Due to thisarrangement, yoke (123) translates longitudinally relative to housinghalves (112, 114) when trigger (120) pivots relative to housing halves(112, 114), as shown in FIGS. 44A-44B. Yoke (123) is captured betweenflange (158) and ring (160) of outer tube (152). Thus, yoke (123) willdrive outer tube (152) to translate relative to body (110) when yoke(123) translates relative to housing halves (112, 114). It shouldtherefore be understood that pivoting of trigger (120) relative tohousing halves (112, 114) will cause longitudinal movement of outer tube(152) relative to body (110), thereby pivoting clamp arm (182) towardand away from blade (190). A return spring (118) resiliently biases yoke(123) trigger (120), and outer tube (152) distally, thereby resilientlybiasing clamp arm (182) to the normal open position shown in FIG. 6A. Asnoted above, trigger (120) includes an integral tab (122) that protrudesproximally from housing halves (112, 114). As trigger (120) is pivoted,the corresponding movement of tab (122) is detected in reusable assembly(200) as will be described in greater detail below.

III. Reusable Assembly of Exemplary Ultrasonic Surgical Instrument

FIGS. 45-47 show reusable assembly (200) in greater detail. As notedabove, reusable assembly (200) comprises a pair of complementary handlehousings (202). Housings (202) together define a pistol grip (204), anupper window (206), and a distal recess (208). Reusable assembly (200)also includes a pair of side buttons (220). Side buttons (220) includeproximally extending stems (222). Side buttons (220) are operable to beactuated inwardly relative to housings (202). The inward actuation ofside buttons (220) causes corresponding movement of stems (222). Stems(222) are located within a sensor region (224) of reusable assembly(200). In some versions, stems (222) include integral magnets and halleffect sensors are located in sensor region (224). The hall effectsensors are configured to detect actuation of side buttons (220) bydetecting field changes caused by movement of the magnets of stems(222). In some other versions, sensor region (224) includes one or morereed switches that are activated by movement of stems (222) caused byactuation of side buttons (220). Other suitable components andtechniques that may be used to detect actuation of side buttons (220)will be apparent to those of ordinary skill in the art in view of theteachings herein. In some variations, side buttons (220) areincorporated into disposable assembly (100) instead of beingincorporated into reusable assembly (200).

As shown in FIG. 46, when body (110) of disposable assembly (100) isinserted in recess (208), the proximal end of tab (122) and the proximalend of arm (128) are also positioned in sensor region (224) of reusableassembly (200). Thus, when trigger (120) is actuated as shown in FIGS.44A-44B, one or more sensors in sensor region (224) may detect suchactuation of trigger (120). Similarly, when button (126) is actuated asshown in FIGS. 44B-44C, one or more sensors in sensor region (224) maydetect such actuation of button (126). Such sensors may include one ormore hall effect sensors, one or more reed switches, and/or any othersuitable kinds of sensors. Various suitable components and techniquesthat may be used to detect actuation of trigger (120) and button (126)will be apparent to those of ordinary skill in the art in view of theteachings herein.

When sensors detect actuation of trigger (120), button (126), or buttons(220), such detection may be communicated to generator (230). Generator(230) may include a control logic (e.g., microprocessor, ASIC, and/orother hardware, etc.) that is operable to execute one or more controlalgorithms in response to actuation of trigger (120), button (126), orbuttons (220). Such a control algorithms may also factor in variousother conditions, including but not limited to the impedance of tissueengaged by end effector (180). By way of example only, generator (230)may be configured at least partially in accordance a GEN 300 sold byEthicon Endo-Surgery, Inc. of Cincinnati, Ohio. In addition or in thealternative, generator (230) may be constructed in accordance with atleast some of the teachings of U.S. Pub. No. 2011/0087212, entitled“Surgical Generator for Ultrasonic and Electrosurgical Devices,”published Apr. 14, 2011, the disclosure of which is incorporated byreference herein. It should also be understood that at least some of thefunctionality of generator (230) may be integrated into a module that isseparate from reusable assembly (200). Still other suitable forms thatgenerator (230) may take, as well as various features and operabilitiesthat generator (230) may provide, will be apparent to those of ordinaryskill in the art in view of the teachings herein.

An operator may activate buttons (126, 220) to selectively activatetransducer assembly (240) to thereby activate ultrasonic blade (190).Buttons (126, 220) of the present example are positioned such that anoperator may readily fully operate instrument (10) with a single hand.For instance, the operator may position their thumb about pistol grip(204), position their middle, ring, and/or little finger about trigger(120), and manipulate button (126) using their index finger. Theoperator may also use their thumb or index finger to manipulate eitherbutton (220). Of course, any other suitable techniques may be used togrip and operate instrument (204); and buttons (126, 220) may be locatedat any other suitable positions. In some versions, button (126)activates ultrasonic blade (190) at a low power and buttons (220)activate ultrasonic blade (190) at a high power. In some other versions,instrument (10) is operable to apply RF energy to tissue via endeffector (180), in addition to providing ultrasonic energy at blade(190). In some such versions, buttons (220) are operable to selectivelyapply such RF energy. By way of example only, buttons (220), button(126), generator (230), and associated components may be operable inaccordance with at least some of the teachings of U.S. Pub. No.2015/0141981, entitled “Ultrasonic Surgical Instrument withElectrosurgical Feature,” published May 21, 2015, the disclosure ofwhich is incorporated by reference herein.

Battery (205) is fully contained in pistol grip (204) and is configuredto provide sufficient power to drive generator (230) in the presentexample. In some versions, battery (205) is rechargeable. In addition orin the alternative, housings (202) may be configured to permitremovability/replacement of battery (205). In addition or in thealternative, reusable portion (200) may include a feature (e.g., cableport, inductive coupling coil, etc.) enabling battery (205) to berecharged. Such recharging may be performed before and/or afterinstrument (10) is used in a surgical procedure. As yet another merelyillustrative example, a recharge port may enable an operator to provideoperational power to generator (230) via a cable. Such wired power maybe used to recharge battery (205) while also providing operational powerto generator (230). By way of example only, instrument (10) mayincorporate battery (205) in accordance with at least some of theteachings of U.S. Pub. No. 2014/0207124, entitled “Surgical Instrumentwith Selectable Integral or External Power Source,” published Jul. 24,2014, the disclosure of which is incorporated by reference herein. Insome other variations, battery (205) is omitted altogether, such thatgenerator (230) receives electrical power via cable or in some otherfashion.

While generator (230) is fixedly secured within housings (202),transducer assembly (240) is operable to rotate within housings (202).As shown in FIGS. 48-49, generator (230) is coupled with transducerassembly (240) via a spindle (232), such that transducer assembly (240)receives electrical power from generator (230) via spindle (232).Spindle (232) is an integral feature of transducer assembly (240) thatis rotatable within generator (230) while maintaining electricalcontinuity between generator (230) and transducer assembly (240). Itshould be understood that slip rings and/or other kinds of couplings maybe used to maintain electrical continuity between wires, traces, and/orother kinds of electrical conduits in spindle (232) and electricalcomponents in generator (230). Various suitable features andrelationships will be apparent to those of ordinary skill in the art inview of the teachings herein.

As best seen in FIGS. 49-50, transducer assembly (240) of the presentexample comprises a proximal casing (242), a distal casing (244), amount (246), a head (248), a bolt (250), an endmass (252), a set ofpiezoelectric discs (254), and a horn (256). Casings (242, 244) arethreadably coupled together and contain mount (246), head (248), bolt(250), endmass (252) and piezoelectric discs (254). Distal casing (244)includes an annular flange (241) and an angularly spaced array oflongitudinally extending splines (243). Mount (246) is interposedbetween an outer diameter of horn (256) and an inner diameter of distalcasing (244). Mount (246) thereby provides structural support for horn(256) in casing (244). Mount (246) is fixedly secured to horn (256) andto casing (244), such that the contents within casings (242, 244) rotateunitarily with casings (242, 244). Mount (246) nevertheless providesacoustic isolation of the contents of within casings (242, 244) relativeto casings (242, 244). In the present example, mount (246) is located ata longitudinal position corresponding to a node associated withultrasonic vibrations that are communicated through horn (256) whenultrasonic transducer assembly (240) is activated.

Bolt (250) compresses piezoelectric discs (254) between horn (256) andendmass (252). Head (248) is configured to provide electrical couplingbetween piezoelectric discs (254) and spindle (232). When piezoelectricdiscs (254) receive electrical power from generator (230) via spindle(232) and head (248), piezoelectric discs (254) vibrate ultrasonically.These ultrasonic vibrations are communicated to horn (256). Horn (256)communicates these ultrasonic vibrations to waveguide (192) whendisposable assembly (100) is coupled with reusable assembly (200). Toprovide such communication, the distal end of horn (256) includes athreaded recess (258), which is configured to threadably receivethreaded stud (196) of waveguide (192). As will be described as greaterdetail below, torque wrench assembly (260) is configured to rotatablydrive threaded stud (196) into threaded recess (258) with an appropriateamount of torque, avoiding a condition where waveguide (192) isover-torqued relative to horn (256).

As shown in FIGS. 49-51, torque wrench assembly (260) of the presentexample comprises a pawl ring (270) and a drive member (280). FIGS.52-56 show pawl ring (270) in greater detail. Pawl ring (270) of thisexample comprises an outer annular flange (272). Flange (272) includes anotch (273) that is configured to receive a complementary boss rail (notshown) formed in housing (202). This relationship provides a rotationalgrounding for pawl ring (270), such that pawl ring (270) is preventedfrom rotating within housing (202). Nevertheless, the relationshipbetween the boss rail and notch (273) enables pawl ring (270) totranslate longitudinally within housing (202). Pawl ring (270) of thepresent example further comprises a first resilient arm (274) and asecond resilient arm (278). Resilient arm (274) includes a pawl (275)and a latch (276). Pawl (275) is directed radially inwardly and extendslongitudinally. Latch (276) is directed radially inwardly and extendstransversely. Resilient arm (274) is resiliently biased to assume theposition shown in FIGS. 52-56. However, resilient arm (274) is operableto flex outwardly as will be described in greater detail below. Secondresilient arm (278) also includes a pawl (279), which is directedradially inwardly and extends longitudinally. Resilient arm (278) isresiliently biased to assume the position shown in FIGS. 52-56. However,resilient arm (278) is operable to flex outwardly as will be describedin greater detail below. Pawl ring (270) also includes an upwardlyextending tab (261). As shown in FIGS. 8, 45-47, 60A-61C, and 63-64, tab(261) is located within upper window (206) of housing (202), such thatan operator may engage tab (261) to slide pawl ring (270) longitudinallyas will be described in greater detail below.

FIGS. 57-59 show drive member (280) in greater detail. Drive member(280) of this example comprises an angularly spaced array oflongitudinally extending splines (282), a proximal outer annular flange(284), an intermediate flange (285), a latching flange (286), and anangularly spaced array of rigid pawls (288). Drive member (280) ispositioned in housing (202) such that integral boss (212) is capturedbetween flanges (284, 285). Integral boss (212) thus prevents drivemember (280) from translating relative to housing (202). However,integral boss (212) permits drive member (280) to rotate relative tohousing (202). Pawls (288) are directed radially outwardly and extendlongitudinally. Splines (282) of drive member (280) are configured tomesh with splines (242) of distal casing (244) of transducer assembly(240). Due to this engagement, drive member (280) rotates unitarily withtransducer assembly (240). However, this engagement still permitstransducer assembly (240) to translate longitudinally relative to drivemember (280). Pawls (288) of drive member (280) are configured tointeract with pawls (275, 279) of pawl ring (270) during coupling ofwaveguide (190) with horn (256), as will be described in greater detailbelow.

As shown in FIGS. 8 and 47, a coil spring (262) is interposed betweenintegral boss (216) of housing (202) and flange (241) of casing (244).Coil spring (262) is resiliently biased to urge transducer assembly(240) distally within housing (202). However, integral boss (214) isconfigured to engage flange (241) of casing (244) to restrict distalmovement of transducer assembly (240) in housing (202). Similarly, asalso shown in FIGS. 8 and 47, a coil spring (264) is interposed betweenintegral boss (212) of housing (202) and flange (272) of pawl ring(270). Coil spring (264) thus urges pawl ring (270) distally withinhousing (202). However, integral boss (210) is configured to engageflange (272) of pawl ring (270) to restrict distal movement of pawl ring(270) in housing (202). It should be understood that one or both of coilsprings (262, 264) are intentionally omitted from various drawings ofthe present disclosure for clarity.

IV. Coupling of Acoustic Drivetrain

FIGS. 60A-64 show how torque wrench assembly (260) operates tomechanically and acoustically couple waveguide (192) with horn (256) inthe present example. In particular, FIGS. 60A and 61A show reusableassembly (200) in a mode where reusable assembly (200) is ready toreceive disposable assembly (100). In this mode, pawl ring (270) ispositioned proximally in housing (202), as indicated by the proximalpositioning of tab (261) in upper window (206) of housing (202). Whenthe operator wishes to couple disposable assembly (100) with reusableassembly (200), the operator first inserts the proximal end of body(110) into distal recess (208) of reusable assembly (200), as shown inFIGS. 60B and 61B. At this stage, threaded stud (196) of waveguide (192)is longitudinally aligned with threaded recess (258) of horn (256) andis in contact with the distal end of horn (256). In order to threadablydrive stud (196) into recess (258), the operator grasps reusableassembly (200) with one hand and knob (156) with the other hand, thenrotates knob (156) relative to reusable assembly (200) to rotate shaftassembly (150) relative to reusable assembly (200), about thelongitudinal axis of shaft assembly (150).

FIGS. 62A-62F show key interactions that occur while shaft assembly(150) is being rotated relative to reusable assembly (200) to threadablydrive stud (196) into recess (258). As noted above, transducer assembly(240) and drive member (280) are rotatable within housing (202) whilepawl ring (270) is not rotatable within housing (202). As also notedabove, transducer assembly (240) and pawl ring (270) are translatablewithin housing (202) while drive member (280) is not translatable withinhousing (202). FIG. 62A shows torque wrench assembly (260) in a statewhere no pawls (288) of drive member (280) are in contact with eitherpawl (275, 279) of pawl ring (270). Thus, as the operator rotates shaftassembly (150) through a first range of motion (e.g., while bearingproximally on disposable assembly (100)), friction may transfer suchrotation to transducer assembly (240) and drive member (280). This maycause transducer assembly (240) and drive member (280) to rotate to theposition shown in FIG. 62B. In this state, a pawl (288) of drive member(280) is in contact with pawl (279) of pawl ring (270). Pawls (288, 279)thereby cooperate to provide a rotational ground for transducer assembly(240) and drive member (280). In other words, transducer assembly (240)and drive member (280) are rotationally grounded relative to housing(202) at this stage. The rotational grounding of drive member (280) isprovided to transducer assembly (240) due to the meshing of splines(243, 282).

As the operator continues to rotate shaft assembly (150) through asecond range of motion while pawls (288, 279) cooperate to provide arotational ground for drive member (280) and transducer assembly (240),stud (196) is threadably driven into recess (258). In particular, whilewaveguide (192) remains longitudinally stationary relative to housing(202), transducer assembly (240) advances distally within housing (202)to permit driving of stud (196) into recess (258). As noted above, coilspring (262) resiliently biases transducer assembly (240) distally topromote this distal advancement of transducer assembly (240) withinhousing (202). The configuration of splines (243, 282) further permitstransducer assembly (240) to translate longitudinally relative to drivemember (280) while maintaining the rotary coupling of transducerassembly (240) with drive member (280).

Once stud (196) reaches a certain degree of insertion into recess (258),the fit between waveguide (192) and horn (256) begins to tighten,resulting in an increase in torque that is applied through the pawl(288) that is engaged with pawl (279). This eventually causes resilientarm (278) to deflect radially outwardly, as shown in FIG. 62C. Pawls(288, 279) include complementary cam surfaces that cooperate to providesuch deflection of resilient arm (278) once the coupling betweenwaveguide (192) and horn (256) reaches a certain torque level. As theoperator continues to rotate shaft assembly (150), pawl (288) eventuallyclears pawl (279), at which point the resilience of arm (278) drivespawl (279) back radially inwardly as shown in FIG. 62D. This action ofpawl (279) may create a snapping/clicking sound and/or asnapping/clicking tactile sensation that may be felt by the handgrasping reusable assembly (200) and/or the hand grasping knob (156).The operator is thus alerted that the coupling of waveguide (192) andhorn (256) is close to reaching a desirable level of torque.

As the operator continues to rotate shaft assembly (150), that same pawl(288) of drive member (280) encounters pawl (275) of pawl ring (270).Again through a camming action between pawls (288, 275), pawl (288)causes resilient arm (274) to deflect radially outwardly, as shown inFIG. 62E. As the operator continues to rotate shaft assembly (150), pawl(288) eventually clears pawl (275), at which point the resilience of arm(274) drives pawl (275) back radially inwardly as shown in FIG. 62F.This action of pawl (275) may create a snapping/clicking sound and/or asnapping/clicking tactile sensation that may be felt by the handgrasping reusable assembly (200) and/or the hand grasping knob (156).The operator is thus alerted that the coupling of waveguide (192) andhorn (256) is has reached a desirable level of torque. In other words,the operator is alerted by a set of two snapping/clicking sounds and/ortactile sensations. Of course, torque wrench assembly (260) mayalternatively be configured to provide any other suitable number ofsnapping/clicking sounds and/or tactile sensations to alert the operatorthat the coupling of waveguide (192) and horn (256) is has reached adesirable level of torque.

FIG. 63 shows another condition that occurs when the coupling processreaches the stage shown in FIG. 62E. As noted above, resilient arm (274)is deflected radially outwardly at this stage, due to a camming actionbetween pawls (288, 275). As a result of this deflection, and as shownin FIG. 63, latch (276) of pawl ring (270) is positioned to clearlatching flange (286) of drive member (280). With latch (276) disengagedfrom latching flange (286), coil spring (264) drives pawl ring (270)distally, to the position shown in FIGS. 60C and 61C. It should beunderstood that coil spring (264) is intentionally omitted from FIGS.60C, 61C, and 63 for clarity. It should also be understood that, duringthe stages shown in FIGS. 60A-60B, 61A-61B, and 62A-62D, latch (276) andlatching flange (286) cooperate to maintain the longitudinal position ofpawl ring (270) in housing (202), despite the distal bias provided bycoil spring (264).

When pawl ring (270) is in the distal position as shown in FIGS. 60C and61C, tab (261) is also in a distal position within upper window (206).Thus, in addition to (or in lieu of) observing audible/tactileclicks/snaps, the operator may observe the longitudinal position of tab(261) in upper window (206) to determine whether waveguide (192) iscoupled with horn (256) at a desired level of torque.

Also when pawl ring (270) is in the distal position as shown in FIGS.60C and 61C, pawls (275, 279) extend along a longitudinal range that isdistal to the longitudinal range along which pawls (288) extend. Inother words, when the operator rotates shaft assembly (150) afterreaching the stage shown in 60C and 61C, pawls (288) will not engagepawls (275, 279). The operator may thus freely use knob (156) toreorient end effector (180) about the longitudinal axis of shaftassembly (150) during a surgical procedure. It should be understood fromthe foregoing that the same knob (156) that is used to rotate shaftassembly (150) to reorient end effector (180) about the longitudinalaxis of shaft assembly (150) may also be used to rotate shaft assembly(150) to threadably couple waveguide (192) with horn (256). It shouldalso be understood from the foregoing that the rotational groundingrequired to provide threaded coupling of waveguide (192) with horn (256)is fully integrated and contained in housing (202) of reusable assembly(200). In other words, the operator does not need to grasp an otherwiserotatable feature and hold that feature stationary while rotating knob(156) to threadably couple waveguide (192) with horn (256).

After a surgical procedure is complete, or even during a surgicalprocedure (e.g., to clean one or more portions of shaft assembly (150)as described above, etc.), it may be desirable to remove disposableassembly (100) from reusable assembly (200). In order to accomplishthis, the operator may slide tab (261) proximally in upper window (206),as shown in FIG. 64. Due to complementary cam features of latch (275)and latching flange (286), the resulting proximal movement of pawl ring(270) causes latch (275) to deflect outwardly and then snap back intoplace to re-engage flange (286). Pawl ring (270) is thereby retained inthe proximal position. With pawl ring (270) back in this proximalposition, pawls (288) are again longitudinally positioned to engage pawl(275). In particular, pawl (288) will eventually engage pawl (275) in amanner similar to that shown in FIG. 62F. Thus, when the operatorrotates shaft assembly (150) counterclockwise relative to reusableassembly (200), pawl (275) will provide a rotational ground fortransducer assembly (240). Moreover, resilient arm (274) will notdeflect outwardly as the operator rotates shaft assembly (150)counterclockwise to unscrew stud (196) from recess (258). Once stud(196) is unscrewed from recess (258), the operator may pull disposableassembly (100) from reusable assembly (200). The same disposableassembly (100) or another disposable assembly (100) may then bere-coupled with reusable assembly (200), using the same processdescribed above.

V. Exemplary Alternative Ultrasonic Surgical Instrument with ActuatedPort Cover

FIGS. 65-66 show an exemplary alternative ultrasonic surgical instrument(300). Instrument (300) of this example is substantially identical toinstrument (10) described above, except as otherwise described below.For instance, like instrument (10) described above, instrument (300) ofthe present example comprises a disposable assembly (400) and a reusableassembly (500). The distal portion of reusable assembly (500) isconfigured to removably receive the proximal portion of disposableassembly (400), as seen in FIGS. 65-66, to form instrument (300). To theextent that the following discussion omits various details of instrument(300), it should be understood that instrument (300) may incorporate thevarious details described above with respect to instrument (10).Alternatively, other suitable details will be apparent to those ofordinary skill in the art in view of the teachings herein.

A. Disposable Assembly of Exemplary Alternative Ultrasonic SurgicalInstrument

FIGS. 67-73 show disposable assembly (400) in greater detail. Disposableassembly (400) of the present example comprises a body portion (410), ashaft assembly (450) extending distally from body portion (410), and anend effector (480) located at the distal end of shaft assembly (450).Body portion (410) comprises a pair of housing halves (412, 414). Asbest seen in FIG. 68, housing halves (412, 414) together define an upperopening (416), as will be described in greater detail below. As bestseen in FIGS. 69-70, housing half (414) also defines a cam ramp (418).It should be understood that housing half (412) may also define asimilar cam ramp to correspond with cam ramp (418) of housing half(414). Cam ramp (418) will be described in greater detail below.

FIGS. 71-73 show a coupling assembly (420) that is incorporated intoshaft assembly (450) in the present example. Coupling assembly (420)includes an upper member (422) and a lower member (424). As best seen inFIG. 73, members (422, 424) together define an annular recess (425).Annular recess (425) is configured to receive a corresponding annularflange (427) of a knob (456) of shaft assembly (456). Thus, couplingassembly (420) translates unitarily with knob (456). However, knob (456)rotates freely relative to coupling assembly (420) in this example.Upper member (422) includes a proximally extending arm (426). Arm (426)has an integral latching feature (428), as will be described in greaterdetail below. Arm (426) is resiliently biased to assume the upwardpositioning shown in FIGS. 72-73. However, depending on the longitudinalposition of coupling assembly (420) in body (410), cam ramp (418) maybear downwardly on arm (426) to deflect arm (426) downwardly from itsnatural position. Longitudinal movement of coupling assembly (420) inbody (410) will be described in greater detail below.

The other components of disposable assembly (400) are substantiallyidentical to corresponding components of disposable assembly (100)described above.

B. Reusable Assembly of Exemplary Alternative Ultrasonic SurgicalInstrument

FIGS. 74-78 show reusable assembly (500) in greater detail. Reusableassembly (500) of this example comprises a battery (505), a generator(530), an ultrasonic transducer assembly (540), and a torque wrenchassembly (560). Torque wrench assembly (560) is operable to couple awaveguide of shaft assembly (450) with an ultrasonic transducer horn(556) of transducer assembly (540). Torque wrench assembly (560) of thepresent example comprises a pawl ring (570), among other components.Those other components, including a drive member (580), aresubstantially identical to corresponding components of torque wrenchassembly (260) described above.

FIGS. 75-78 show pawl ring (570) in greater detail. Pawl ring (570) ofthe present example comprises an annular flange (572), a first resilientarm (574) and a second resilient arm (578). Resilient arm (574) includesa pawl (575) and a latch (576). Pawl (575) is directed radially inwardlyand extends longitudinally. Latch (576) is directed radially inwardlyand extends transversely. Resilient arm (574) is resiliently biased toassume the position shown in FIGS. 75-78. However, resilient arm (574)is operable to flex outwardly as will be described in greater detailbelow. Second resilient arm (578) also includes a pawl (579), which isdirected radially inwardly and extends longitudinally. Resilient arm(578) is resiliently biased to assume the position shown in FIGS. 75-78.However, resilient arm (578) is operable to flex outwardly as will bedescribed in greater detail below. Pawl ring (570) also includes adistally projecting latch (571).

C. Coupling of Alternative Disposable Assembly with Alternative ReusableAssembly

FIGS. 79A-80D show how torque wrench assembly (560) operates tomechanically and acoustically couple a waveguide of shaft assembly (450)with horn (556) in the present example. In particular, FIGS. 79A and 80Ashow reusable assembly (500) in a mode where reusable assembly (500) isready to receive disposable assembly (400). In this mode, pawl ring(570) is positioned proximally in housing (502). When the operatorwishes to couple disposable assembly (400) with reusable assembly (500),the operator first inserts the proximal end of body (410) into distalrecess (508) of reusable assembly (500), as shown in FIGS. 79B and 80B.At this stage, a threaded stud of the waveguide of shaft assembly (450)is longitudinally aligned with a threaded recess of horn (556) and is incontact with the distal end of horn (556). As the operator inserts theproximal end of body (410) into distal recess (508) of reusable assembly(500), latch (571) of pawl ring (570) enters upper opening (416) of body(410).

The operator then pulls knob (456) proximally, as shown in FIGS. 79C and80C. This drives knob (456) and coupling assembly (420) proximallyrelative to other components of shaft assembly (450). As a result ofthis proximal movement of coupling assembly (420), latching feature(428) of arm (426) engages latch (571) of pawl ring (570). The upwardbias of arm (426) maintains engagement between latching feature (428)and latch (571) when knob (456) and coupling assembly (420) are in theproximal position relative to housing (502). Thereafter, in order tothreadably couple the waveguide with horn (556), the operator graspsreusable assembly (500) with one hand and knob (456) with the otherhand, then rotates knob (456) relative to reusable assembly (500) torotate shaft assembly (450) relative to reusable assembly (500), aboutthe longitudinal axis of shaft assembly (550). As described above withrespect to torque wrench assembly (260), torque wrench assembly (560) ofthis example provides a rotational ground for transducer assembly (540)as shaft assembly (450) is rotated. During this process, a pawl of drivemember (580) eventually engages pawl (579) of pawl ring (570), then pawl(575) of pawl ring (570), to provide the two snaps/clicks associatedwith a proper level of torque between the waveguide and horn (556). Thisinteraction may be substantially identical to that described above withreference to FIGS. 62A-F. It should therefore be understood that latch(576) of pawl ring (570) will eventually be driven out of engagementwith latch flange (586) of drive member (580). When latch (576) hasdisengaged latch flange (586), a coil spring (564) will drive pawl ring(570) distally in housing (502), as shown in FIGS. 79D and 80D.

With pawl ring (570) in the distal position as shown in FIGS. 79D and80D, pawls (575, 579) are longitudinally positioned such that they willnot engage pawls of drive member (580). The combination of shaftassembly (450) and transducer assembly (540) is thus free to rotate as aunit relative to housing (502). As can also be seen in FIGS. 79A and80D, when pawl ring (570) travels distally, latch (571) engages cam ramp(418) and is urged upwardly. In particular, cam ramp (418) disengageslatch (571) from latching feature (428) of arm (426). This enables knob(450) to be advanced distally relative to housing (502), without alsoadvancing pawl ring (570) distally any further. It should be understoodthat instrument (300) is ready for use in a surgical procedure afterreaching the stage shown in FIGS. 79D and 80D. The operator may thusfreely use knob (456) to reorient end effector (480) about thelongitudinal axis of shaft assembly (450) during a surgical procedure.

It should be understood from the foregoing that the same knob (456) thatis used to rotate shaft assembly (450) to reorient end effector (480)about the longitudinal axis of shaft assembly (450) may also be used torotate shaft assembly (450) to threadably couple the waveguide with horn(556). It should also be understood from the foregoing that therotational grounding required to provide threaded coupling of thewaveguide with horn (556) is fully integrated and contained in housing(502) of reusable assembly (500). In other words, the operator does notneed to grasp an otherwise rotatable feature and hold that featurestationary while rotating knob (456) to threadably couple the waveguidewith horn (556).

After a surgical procedure is complete, or even during a surgicalprocedure (e.g., to clean one or more portions of shaft assembly (450)as described above, etc.), it may be desirable to remove disposableassembly (400) from reusable assembly (500). In order to accomplishthis, the operator may slide knob (456) proximally again relative tohousing (502). Sliding knob (456) proximally relative to housing (502)causes coupling assembly (420) to slide proximally relative to housing(502). As coupling assembly (420) slides proximally relative to housing(502), arm (426) engages pawl ring (570) and drives pawl ring proximallyrelative to housing (502). Due to complementary cam features of latch(576) and latching flange (586), the proximal movement of pawl ring(570) causes latch (576) to deflect outwardly and then snap back intoplace to re-engage flange (586). Pawl ring (570) is thereby retained inthe proximal position. With pawl ring (570) back in this proximalposition, the pawls of drive member (280) are again longitudinallypositioned to engage pawl (575). In particular, a pawl of drive member(280) will eventually engage pawl (575) in a manner similar to thatshown in FIG. 62F. Thus, when the operator rotates shaft assembly (450)counterclockwise relative to reusable assembly (500), pawl (575) willprovide a rotational ground for transducer assembly (540). Moreover,resilient arm (574) will not deflect outwardly as the operator rotatesshaft assembly (450) counterclockwise to unscrew the waveguide from horn(556). Once the waveguide is unscrewed from horn (556), the operator maypull disposable assembly (400) from reusable assembly (500). The samedisposable assembly (400) or another disposable assembly (400) may thenbe re-coupled with reusable assembly (500), using the same processdescribed above.

VI. Exemplary Disposable Assembly with Usage Indicator

In some instances, it may be desirable to provide some form of visualindication that shows whether and/or how many times a disposableassembly (100, 400) has been used. Such indication may be observed bythe operator to determine that the disposable assembly (100, 400) shouldno longer be used, such that the disposable assembly (100, 400) shouldbe replaced. By way of example only, a usage indicator may be configuredto indicate the number of uses that have occurred, the number of usesremaining, and/or the end of the life of the disposable assembly (100,400). A usage indicator may be temporary or permanent.

FIG. 81 shows an exemplary alternative disposable assembly (600) thatmay readily incorporated into instrument (10) in place of disposableassembly (100). Disposable assembly (600) of this example issubstantially identical to disposable assembly (100) described above.For instance, disposable assembly (600) includes a pivotable trigger(620), a mode selection knob (630), and a shaft assembly (650), whichare identical to trigger (120), mode selection knob (130), and shaftassembly (150), respectively. However, unlike disposable assembly (100),disposable assembly (600) of this example further includes a usageindicator (670). Usage indicator (670) of this example comprises alinearly arranged array of discrete visual indicators (672). By way ofexample only, usage indicator (670) may be configured such that thefirst visual indicator (672) activates the first time disposableassembly (600) is used, the second visual indicator (672) activates thesecond time disposable assembly (600) is used, and so on. Thenon-activated visual indicators (672) thus indicate the remaining numberof uses available. When all visual indicators (672) are activated, thiswill indicate that disposable assembly (600) has reached the end of itslife, such that disposable assembly (600) should be disposed of (andreplaced with a new disposable assembly (600), if the operator wishes tocontinue using instrument (10)).

Visual indicators (672) may be energized by a battery (e.g., coin cellor button cell, etc.) located in disposable assembly (600), an energizedcapacitor located in disposable assembly (600), an electrical connectorbetween disposable assembly (600) and reusable assembly (200, 500),and/or using any other suitable power source in any other suitablelocation. In versions where an electrical connector is provided betweendisposable assembly (600) and reusable assembly (200, 500), theelectrical connector may transmit voltage and current from reusableassembly (200, 500) to disposable assembly (600) while the instrument isassembled, based on meeting the appropriate usage criteria. Visualindicators (672) may be located on a surface that is only visible whendisposable assembly (600) is removed from reusable assembly (200, 500),as noted below. Various suitable electrical components that may beincorporated into usage indicator (670) in order to successivelyilluminate Visual indicators (672) in response to usage of instrument(10) will be apparent to those of ordinary skill in the art in view ofthe teachings herein.

While visual indicators (672) are shown as being arranged in a lineararray, it should be understood that any other suitable arrangement maybe used. Similarly, while visual indicators (672) are shown as beingpositioned on the lateral side of disposable assembly (600), visualindicators (672) may instead be positioned at any other suitablelocation(s) on disposable assembly (600). In some versions, visualindicators (672) are visible when disposable assembly (600) is coupledwith reusable assembly (200). In some other versions, visual indicators(672) are obscured when disposable assembly (600) is coupled withreusable assembly (200), such that visual indicators (672) are onlyvisible when disposable assembly (600) is decoupled from reusableassembly (200).

FIG. 82 shows another exemplary alternative disposable assembly (700)that may readily incorporated into instrument (10) in place ofdisposable assembly (100). Disposable assembly (700) of this example issubstantially identical to disposable assembly (100) described above.For instance, disposable assembly (700) includes a pivotable trigger(720), a mode selection knob (730), and a shaft assembly (750), whichare identical to trigger (120), mode selection knob (130), and shaftassembly (150), respectively. However, unlike disposable assembly (100),disposable assembly (700) of this example further includes a usageindicator (770). Usage indicator (770) of this example comprises asingle indicator that is activated when the end of life of disposableassembly (700) has been reached. In some versions, usage indicator (770)comprises an LED or other light source. In the present example, usageindicator (770) comprises one or more thermochromic materials (772).Thermochromic material (772) is configured to change in visualappearance in response to an increase in temperature. For instance,before disposable assembly (700) is used, thermochromic material (772)may be black; and then turn red or some other color after disposableassembly (700) is used. Various suitable kinds of materials andcombinations of materials that may be used to form thermochromicmaterial (772) will be apparent to those of ordinary skill in the art inview of the teachings herein. It should also be understood that visualindicator (672) described above may comprise a thermochromic material.

In some versions, thermochromic material (772) is coupled with one ormore features of disposable assembly (700) that are electricallyactivated during use of an instrument (10) incorporating disposableassembly (700). For instance, a resistor may be used to generate heat inresponse to electrical activation of components in disposable assembly(700) during use of an instrument (10) incorporating disposable assembly(700). Other suitable ways in which thermochromic material (772) may beheated due to use of an instrument (10) incorporating disposableassembly (700) will be apparent to those of ordinary skill in the art inview of the teachings herein. It should also be understood that someversions of thermochromic material (772) may be configured to maintain achanged color even after the temperature falls back to a level where itwas before disposable assembly (700) was used. For instance, beforedisposable assembly (700) is used, thermochromic material (772) may beblack. When thermochromic material (772) is heated in response to use ofdisposable assembly (700), thermochromic material (772) changes red (orsome other color). After disposable assembly (700) is used andthermochromic material (772) cools back down to the same temperature itwas at before disposable assembly (700) was used, the color ofthermochromic material (772) may remain red (or some other colorindicating use).

By way of example only, thermochromic material (772) may comprise athermochromic material by LCR Hallcrest of Glenview, Ill. Other suitableforms that thermochromic material (772) may take, as well as variousother ways in which thermochromic material (772) may be incorporatedinto disposable assembly (700), will be apparent to those of ordinaryskill in the art in view of the teachings herein.

In addition to or in lieu of using thermochromic material (772), usageindicator (770) may incorporate an exposed section of electrochromicmaterial. Such electrochromic material may change color in response toan applied voltage and/or current. Such electrochromic material may becoupled with one or more features of disposable assembly (700) that areelectrically activated during use of an instrument (10) incorporatingdisposable assembly (700). Various suitable ways in which anelectrochromic material may be incorporated into disposable assembly(700) to visually indicate use of disposable assembly (700) will beapparent to those of ordinary skill in the art in view of the teachingsherein. By way of example only, the electrochromic material may comprisean electrochromic ink by Chameleon Optics, Inc. of Bethlehem, Pa. Othersuitable forms that electrochromic material may take, as well as variousother ways in which electrochromic material may be incorporated intodisposable assembly (700), will be apparent to those of ordinary skillin the art in view of the teachings herein.

In addition to or in lieu of using thermochromic material (772) and/orelectrochromic material, usage indicator (770) may incorporate a UVactivated ink, a fuse assembly, and/or various other kinds of featuresthat may provide visual indication that disposable assembly (700) hasbeen used.

While disposable assemblies (600, 700) are both described as substitutesfor disposable assembly (100), it should be understood that disposableassembly (400) may also be modified in accordance with disposableassemblies (600, 700). In other words, disposable assemblies (600, 700)may each be configured to couple with reusable assembly (500).Furthermore, usage indicators (670, 770) as described herein may bereadily incorporated into various other kinds of surgical instruments,including but not limited to electrosurgical instrument, otherultrasonic surgical instruments, surgical stapling and cutting devices(e.g., endocutters, etc.), robotic surgical instruments, etc. Varioussuitable kinds of instruments in which usage indicators (670, 770) maybe incorporated will be apparent to those of ordinary skill in the artin view of the teachings herein.

VII. Exemplary Alternative Ultrasonic Surgical Instrument with RemovableAcoustic Waveguide

FIG. 83 shows an exemplary alternative ultrasonic surgical instrument(800). Instrument (800) of this example is substantially identical toinstrument (10) described above, except as otherwise described below.For instance, like instrument (10) described above, instrument (800) ofthe present example comprises a disposable assembly (1000) and areusable assembly (900). The distal portion of reusable assembly (900)is configured to removably receive the proximal portion of disposableassembly (1000). To the extent that the following discussion omitsvarious details of instrument (800), it should be understood thatinstrument (800) may incorporate the various details described abovewith respect to instrument (10). Alternatively, other suitable detailswill be apparent to those of ordinary skill in the art in view of theteachings herein.

In an exemplary use, assemblies (900, 1000) are coupled together to forminstrument (800) before a surgical procedure, the assembled instrument(800) is used to perform the surgical procedure, and then assemblies(900, 1000) are decoupled from each other for further processing. Insome instances, after the surgical procedure is complete, disposableassembly (1000) is immediately disposed of while reusable assembly (900)is sterilized and otherwise processed for re-use. By way of exampleonly, reusable assembly (900) may be sterilized in a conventionalrelatively low temperature, relatively low pressure, hydrogen peroxidesterilization process. Alternatively, reusable assembly (900) may besterilized using any other suitable systems and techniques (e.g.,autoclave, etc.). In some versions, reusable assembly (900) may besterilized and reused approximately 100 times. Alternatively, reusableassembly (900) may be subject to any other suitable life cycle. Forinstance, reusable assembly (900) may be disposed of after a single use,if desired. While disposable assembly (1000) is referred to herein asbeing “disposable,” it should be understood that, in some instances,disposable assembly (1000) may also be sterilized and otherwiseprocessed for re-use. By way of example only, disposable assembly (1000)may be sterilized and reused approximately 2-30 times, using anysuitable systems and techniques. Alternatively, disposable assembly(1000) may be subject to any other suitable life cycle. It should alsobe understood that, as described above, disposable assembly (1000)and/or reusable assembly (900) includes one or more features that areoperable to track usage of the corresponding assembly (900, 1000), andselectively restrict operability of the corresponding assembly (900,1000) based on use.

A. Reusable Assembly of Exemplary Alternative Ultrasonic SurgicalInstrument

FIGS. 84-86 show reusable assembly (900) in greater detail. Reusableassembly (900) of this example is substantially identical to reusableassembly (200) except for the differences noted below. Reusable assembly(900) comprises a pair of housings (902) that together define a pistolgrip (904). As shown in FIG. 86, reusable assembly (900) comprises atransducer assembly (940) and a torque wrench assembly (960). Transducerassembly (940) is configured and operable just like transducer assembly(240). However, unlike transducer assembly (240), transducer assembly(940) of this example comprises a port (942) that is configured tocouple with a power cable (not shown) that is received through theproximal end of housing (902). Transducer assembly (940) thus receivespower from a source external to instrument (800), such that reusableassembly (900) lacks a generator (230) and battery (205). In somealternative versions, however, reusable assembly (900) may include anintegral generator (230) and battery (205).

Another difference between reusable assembly (900) and reusable assembly(200) is that reusable assembly (900) of this example lacks buttons(220). Instead, buttons (1004) are incorporated into disposable assembly(1000) as described below. However, reusable assembly (900) includesmating features (910, 912) that are configured to mate withcorresponding mating features (1012, 1014) associated with buttons(1002, 1004) of disposable assembly (1000). Mating features (910, 912)thus provide a route for processing user inputs received through buttons(1002, 1004) to activate transducer assembly (940) at an appropriatepower level based on the user inputs. Various suitable ways in whichuser input signals received through mating features (910, 912) may berouted and processed will be apparent to those of ordinary skill in theart in view of the teachings herein.

Torque wrench assembly (960) is configured and operable just like torquewrench assembly (260). In particular, torque wrench assembly (960) isconfigured to ensure that a horn (956) of transducer assembly (940) iscoupled with a threaded stud (1096) of an acoustic waveguide (1092) atan appropriate level of torque. However, torque wrench assembly (960) ofthis example has a pawl ring (970) that is configured slightlydifferently from pawl ring (270) of torque wrench assembly (260). Asbest seen in FIGS. 87-88, pawl ring (970) of this example includes a setof pawls (975, 979) that are configured and operable just like pawls(275, 279) of pawl ring (270). Pawl ring (970) of this example alsoincludes a latch (976) that is configured and operable just like latch(276).

In addition, pawl ring (970) includes a tab (961) that is similar to tab(261). As shown in FIG. 85, tab (961) is accessible through a window(908) defined by housings (902). Tab (961) is coupled with a slider(906), which is configured to be easily manipulated by the operator tomanually slide pawl ring (970) longitudinally via tab (961) as describedabove with reference to FIG. 64. In particular, when the operator wishesto decouple disposable assembly (1000) from reusable assembly (900), theoperator may slide pawl ring (970) proximally by moving slider (906)proximally along housings (902). This may rotationally fix transducerassembly (940) relative to housings (902), allowing the operator tounscrew threaded stud (1096) of waveguide (1092) from horn (956) oftransducer assembly (940).

The main structural difference between pawl ring (970) of this exampleand pawl ring (270) described above is that pawl ring (970) includes aset of rod channels (972) for rotational stability instead of having anotch (273) in a flange (272) for rotational stability. In the presentexample, pawl ring (970) has four rod channels (972), though it shouldbe understood that pawl ring (970) may instead have any other suitablenumber of rod channels (972). As shown in FIG. 86, rod channels (972)are configured to slidably receive rods (920). Rods (920) are fixedlysecured within housings (902). Rods (920) and rod channels (972) areconfigured to enable pawl ring (970) to slide longitudinally withinhousings (902) yet prevent pawl ring (970) from rotating within housings(902). Various other suitable structural features that may be used toprovide such functionality will be apparent to those of ordinary skillin the art in view of the teachings herein.

B. Disposable Assembly of Exemplary Alternative Ultrasonic SurgicalInstrument

FIGS. 89-90B show disposable assembly (1000) in greater detail.Disposable assembly (100) of this example comprises a set of buttons(1002, 1004) as noted above, a pair of housings (1006), a knob assembly(1010), a trigger (1020), a shaft assembly (1050), and an end effector(1080). Buttons (1002, 1004) are operable to selectively activatetransducer assembly (940) as noted above. While only one side button(1004) is shown, it should be understood that another side button (1004)may be included on the obscured side of disposable assembly (1000).Housings (1006) are configured to mate with housings (902) of reusableassembly (1000) to form the full assembly of instrument (800) as shownin FIG. 83. Knob assembly (1010) is configured to rotate shaft assembly(1050) and end effector (1080) about the longitudinal axis of shaftassembly (1050). Trigger (1020) is operable to actuate a clamp arm(1082) of end effector (1080) as will be described in greater detailbelow. Shaft assembly (1050) comprises a plurality of coaxially arrangedcomponents that are operable to communicate ultrasonic vibrations andlongitudinal clamp arm (1082) driving forces as will also be describedin greater detail below.

End effector (1080) comprises clamp arm (1082) and an ultrasonic blade(1090). Clamp arm (1082) is operable to pivot from an open position(FIG. 90A) to a closed position (FIG. 90B). Such pivotal movement isaccomplished through relative longitudinal movement of an inner tube(1070) of shaft assembly (1050) and an outer tube (1052) of shaftassembly (1050). In particular, one portion of clamp arm (1082) ispivotably coupled with the distal end of inner tube (1070). Anotherportion of clamp arm (1082) is pivotably coupled with the distal end ofouter tube (1052). Such coupling may be identical to the couplingbetween clamp arm (182), inner tube (1070), and outer tube (152) asdescribed above and as shown in FIGS. 4-7. Thus, when outer tube (1052)is translated longitudinally while inner tube (1070) remains stationary,clamp arm (1082) pivots toward and away from blade (1090). End effector(1080) may thus receive tissue between clamp arm (1082) and blade (1090)when clamp arm (1082) is in the open position; and clamp the tissuebetween clamp arm (1082) and blade (1090) when clamp arm (1082) isdriven to the closed position. Blade (1090) of this example isconfigured and operable just like blade (1090) described above, suchthat blade (1090) is operable to oscillate at ultrasonic frequencies andthereby sever tissue that is clamped between clamp arm (1082) and blade(1090) as described above. Exemplary features that may be used toactuate clamp arm (1082) will be described in greater detail below.

1. Actuation Components of Disposable Assembly

In the present example, trigger (1020) is operable to actuate clamp arm(1082) by pivoting trigger (1020) toward and away from pistol grip(904). In particular, trigger (1020) is pivotable between a firstposition (FIGS. 91A and 93A) and a second position (FIGS. 91B and 93B).When trigger (1020) is in the first position, clamp arm (1082) is in theopen position (FIG. 90A). When trigger (1020) is in the second position,clamp arm (1082) is in the closed position (FIG. 90B). FIGS. 91A-93Bdepict actuation components that couple trigger (1020) with clamp arm(1082). In particular, trigger (1020) is coupled with clamp arm (1082)via a yoke (1100), a coupling assembly (1110), and outer tube (1052). Asbest seen in FIGS. 93A-93B, trigger (1020) comprises a first arm (1022),a second arm (1024), and a third arm (1026). First arm (1022) ispivotably coupled with housings (1006) via a pin (1021). Trigger (1020)thus pivots about an axis defined by pin (1021). Second arm (1024) ispivotably coupled with a link (1028) via a pin (1023). Third arm (1026)protrudes proximally from disposable assembly (1000). As described abovewith respect to tab (122) of trigger (120), reusable assembly (900) mayinclude a sensor and/or other feature(s) that is/are operable to detectmovement of third arm (1026) to thereby detect actuation of trigger(1020).

As best seen in FIG. 92, yoke (1100) comprises a fork member (1102).Fork member (1102) is configured to couple with a set of flanges (1112)of coupling assembly (1110), such that longitudinal translation of yoke(1100) provides longitudinal translation of coupling assembly (1110).Coupling assembly (1110) is secured to the proximal end of outer tube(1052) as described in greater detail below, such that longitudinaltranslation of coupling assembly (1110) provides longitudinaltranslation of outer tube (1052) to actuate clamp arm (1082). Yoke(1100) defines an elongate slot (1104), a first pin opening (1106) and aset of second pin openings (1108). As best seen in FIGS. 91A-91B, a pin(1007) is slidably disposed in elongate slot (1104). Pin (1007) isfixedly secured within housings (1006) such that pin (1007) slidablysupports yoke (1100). A pin (1008) is secured in pin opening (1106). Pin(1008) is slidably received in elongate channels that are formed inhousings (1006), such that pin (1008) also slidably supports yoke(1100). Yoke (1100) is coupled with link (1028) via a pin (1029), whichis disposed in second pin openings (1108). Link (1028) is pivotablerelative to yoke (1100) about the axis of pin (1029).

As best seen in the transition from FIG. 93A to FIG. 93B, as trigger(1020) is pivoted proximally, second arm (1024) drives pin (1023)upwardly. This upward movement of pin (1023) causes link (1028) to pivotabout both pins (1023, 1029) and also causes link (1028) to drive pin(1029) proximally. As best seen in the transition from FIG. 91A to FIG.91B, this proximal movement of pin (1029) pulls yoke (1100) proximally.The proximal movement of yoke (1100) moves coupling assembly (1110)proximally. The proximal movement of coupling assembly (1110) movesouter tube (1052) proximally. With inner tube (1070) remainingstationary as outer tube (1052) moves proximally, the proximal movementof outer tube (1052) drives clamp arm (1082) from the open position tothe closed position. To return clamp arm (1082) to the open position,trigger (1020) is simply pivoted distally back to the position shown inFIGS. 91A and 93A, which will reverse the above motions. Of course, anyother suitable components and operational sequences may be used toactuate clamp arm (1082).

2. Shaft Assembly Components of Disposable Assembly

FIGS. 94-108 depict various components of shaft assembly (1050). Inparticular, FIGS. 94-95 show how shaft assembly (1050) comprises outertube (1052), inner tube (1070), acoustic waveguide (1092), a waveguideguiding member (1200), yoke coupling assembly (1110), an inner tubecoupling member assembly (1150), a coil spring (1190), a cleaning portbody (1300), and knob assembly (1010). These components are allcoaxially aligned with each other. Each of these components will bedescribed in greater detail below.

FIG. 96 shows yoke coupling assembly (1110) in greater detail. Yokecoupling assembly (1110) of this example comprise a flange assembly(1111), a tube coupling member (1120), a set of wave springs (1140), anut (1142), and a washer (1144). Flange assembly (1111) comprises a setof flanges (1112) that couple with fork member (1102) of yoke (1100) asdescribed above. As shown in FIGS. 96-98, tube coupling member (1120)comprises an elongate cylindraceous body (1122) having a flange portion(1126) at the distal end and a threaded portion (1124) at the proximalend. Body (1122) also defines a pair of elongate, resilient arms (1128).The distal end of each resilient arm (1128) includes an elongate tab(1130). A protrusion (1131) extends inwardly from the proximal end ofeach elongate tab (1130). The distal end of body (1122) further includesa pair of elongate notches (1132). Notches (1132) are angularly offsetfrom arms (1128) by 90°.

As best seen in FIGS. 99-101, tube coupling member (1120) is configuredto couple with a proximal mounting portion (2000) of outer tube (1052).Proximal mounting portion (2000) includes a distal lateral opening(2002), a first pair of proximal lateral openings (2004), a second pairof proximal lateral openings (2006), and an elongate lateral pin opening(2008). Openings (2006) are angularly offset from openings (2004) by90°. Opening (2008) is offset from opening (2002) by 180°. Tube couplingmember (1120) may be coupled with proximal mounting portion (2000) bysliding tube coupling member (1120) distally over the proximal end ofproximal mounting portion (2000). When this is done, arms (1128) willinitially deform outwardly and then snap back into place once elongatetabs (1130) reach openings (2004). Openings (2004) are sized to receivethe full length of elongate tabs (1130) such that tube coupling member(1120) and proximal mounting portion (2000) are longitudinally androtationally fixed together. With tube coupling member (1120) secured toproximal mounting portion (2000), openings (2002, 2006, 2008) are leftexposed; and notches (1132) are angularly and longitudinally alignedwith openings (2006).

Once tube coupling member (1120) is secured to proximal mounting portion(2000), flange assembly (1111) and wave springs (1140) are slid overbody (1122), and then nut (1142) is secured to threaded portion (1124)to capture flange assembly (1111) and wave springs (1140) between nut(1142) and flange portion (1126). Washer (1144) is inserted into theinterior of body (1122) until washer (1144) abuts protrusions (1131).This assembled yoke coupling assembly (1110) is sized to receive innertube (1070) and inner tube coupling member assembly (1150). Before innertube (1070) and inner tube coupling member assembly (1150) are insertedinto yoke coupling assembly (1110), coil spring (1190) is inserted intothe interior of body (1122). Washer (1144) is sized to provide a distalbearing surface for the distal end of coil spring (1190), andprotrusions (1131) provide a distal bearing surface for washer (1144).The proximal end of coil spring (1190) is configured to engage innertube coupling member assembly (1150) as will be described in greaterdetail below, such that coil spring (1190) provides engagement betweenyoke coupling assembly (1110) and inner tube coupling member assembly(1150).

FIGS. 102-103 show inner tube coupling member assembly (1150) in greaterdetail. Inner tube coupling member assembly (1150) is engaged with aproximal mounting portion (2010) of inner tube (1070). Proximal mountingportion (2010) includes a set of proximally projecting resilient arms(2012). Arms (2012) are configured identically to arms (181) describedabove, such that their structural details will not be repeated here.Arms (2012) are configured to engage a pin (1094) of waveguide (1092) aswill be described in greater detail below.

Inner tube coupling member assembly (1150) comprises a cylindraceousbody (1160), a proximal flange member (1170), and a distal deflectormember (1180). Cylindraceous body (1160) defines a first pair of lateralopenings (1162) and a second pair of lateral openings (1164). Openings(1164) are angularly offset from openings (1162) by 90°. Openings (1162)are configured to correspond with pin (1094) of waveguide (1092) andarms (2012) of proximal mounting portion (2010) of inner tube (1070).Openings (1164) are positioned to angularly and longitudinallycorrespond with openings (2006) of proximal mounting portion (2000) ofouter tube (1052). Openings (1164) are also sized to receive latch tabs(1188) of distal deflector member (1180) as will be described in greaterdetail below.

Flange member (1170) is secured to the proximal end of body (1160)through a snap fit in the present example, though it should beunderstood that any suitable structures and techniques may be used tosecure flange member (1170) to body (1160). Flange member (1170)comprises a cylindraceous portion (1172) and a flange portion (1174). Asshown in FIGS. 91A-91B, 93A-93B, and 94, flange portion (1174) isengaged with a resilient latch (1009). Latch (1009) is secured tohousings (1006) and is configured to provide a proximal ground forflange portion (1174) when disposable assembly (1000) is in anoperational mode. However, when disposable assembly (1000) is convertedto a cleaning mode as described in greater detail below, latch (1009)disengages flange portion (1174), allowing flange member (1170) and therest of inner tube coupling member assembly (1150) to travel proximally.As best seen in FIG. 94, the distal edge of cylindraceous portion (1172)is configured to engage the proximal end of coil spring (1190). Itshould be understood that, when trigger (1020) is actuated to closeclamp arm (1082), yoke coupling assembly (1110) will travel proximally,and this proximal travel will compress coil spring (1190) against thedistal edge of cylindraceous portion (1172). Flange member (1170) thusprovides a proximal mechanical ground; and coil spring (1190) therebyimparts a distal bias to yoke coupling assembly (1110). In other words,coil spring (1190) and flange member (1170) cooperate to bias clamp arm(1082) to the open position.

FIG. 104 shows deflector member (1180) in greater detail. Deflectormember (1180) comprises upper and lower ridges (1182) and a pair ofresilient arms (1184). The proximal end of each resilient arm (1184)includes an inwardly directed latch tab (1188) and an outwardly directedguide tab (1186). As noted above, latch tabs (1188) are disposed inopenings (1164) of body (1160) to secure deflector member (1180) to body(1160) in a snap fit manner. Guide tabs (1186) are sized and positionedfor slidable receipt in openings (2006) of proximal mounting portion(2000) of outer tube (1052). Guide tabs (1186) and openings (2006) aresized and configured to enable inner tube coupling member assembly(1150) to slide longitudinally relative to proximal mounting portion(2000) of outer tube (1052). However, the positioning of guide tabs(1186) in openings (2006) provides concomitant rotation of proximalmounting portion (2000) with inner tube coupling member assembly (1150).In other words, tubes (1052, 1070) rotate together due in part to thepositioning of guide tabs (1186) in openings (2006); yet outer tube(1052) may still translate longitudinally relative to inner tube (1070)despite the positioning of guide tabs (1186) in openings (2006). Itshould also be noted that, when disposable assembly (1000) is in anoperational mode, arms (2012) are configured to effectively reach overridges (1182) to engage pin (1094) of waveguide (1092).

As best seen in FIGS. 105-107, waveguide guiding member (1200) of thepresent example comprises a hollow elongate body (1202) having aplurality of cam surfaces (1212, 1214, 1216, 1218, 1220, 1222) on oneside of a channel (1204) and another plurality of cam surfaces (1242,1244, 1246, 1248) on the other side of channel (1204). Body (1202) alsodefines a lateral opening (1270) near the distal end of body (1202). Camsurfaces (1212, 1242) converge at a point (1250) at the proximal end ofbody (1202). Cam surfaces (1222, 1248) converge at an end surface (1260)at the distal end of body (1202).

Cam surface (1212) extends along a helical path in a first angulardirection and leads to cam surface (1214). Cam surface (1214) extendsalong a straight longitudinal path and leads to cam surface (1216). Camsurface (1216) extends along a helical path in the first angulardirection and leads to cam surface (1218). Cam surface (1218) extendsalong a straight longitudinal path and leads to cam surface (1220). Camsurface (1220) extends along a helical path in a second angulardirection and leads to cam surface (1222). Cam surface (1222) extendsalong a straight longitudinal path and leads to end surface (1260).

Cam surface (1242) extends along a helical path in the second angulardirection and leads to cam surface (1244). Cam surface (1244) extendsalong a straight longitudinal path and leads to cam surface (1246). Camsurface (1246) extends along a helical path in the second angulardirection and leads to cam surface (1248). Cam surface (1248) extendsalong a straight longitudinal path and leads to end surface (1260). Aswill be described in greater detail below, cam surfaces (1212, 1214,1216, 1218, 1220, 1222, 1242, 1244, 1246, 1248) cooperate to guide andthereby orient waveguide (1092) at an appropriate angular orientation aswaveguide (1092) is inserted through body (1202).

As best seen in FIG. 108, waveguide (1092) of the present examplecomprises an elastomeric fender (1093), pin (1094), threaded stud(1096), and a laterally extending guide post (1099). Blade (1090) islocated at the distal end of waveguide (1092). As shown in FIG. 94,fender (1093) is coaxially interposed between the outer diameter ofwaveguide (1092) and the inner diameter of inner tube (1070). In thepresent example, fender (1093) comprises an elastomeric material (e.g.,rubber, silicone, etc.) and is located at a position corresponding to anode associated with ultrasonic vibrations that are communicated throughwaveguide (1092). It should be understood that a plurality of fenders(1093) may be located at nodal positions along the length of waveguide(1092). Such fenders (1093) may provide lateral support and/or spacingfor waveguide (1092).

Referring back to FIG. 108, pin (1094) is secured to waveguide (1092) bya set of clips (1097). Clips (1097) are configured to ensure that pin(1094) is centered within the corresponding transverse bore formedthrough waveguide (1092), to secure and support pin (1094) in that bore,and to provide acoustic isolation between waveguide (1092) and pin(1094). Of course, any other suitable structures or features may be usedin addition to or in lieu of clips (1097). In some versions, anelastomeric outer sleeve is positioned about sleeve (1094) and/orelastomeric members positioned about clips (1097). Such an elastomericsleeve and/or members may provide further acoustic isolation of pin(1094) and/or clips (1097) relative to waveguide (1092).

As noted above, stud (1096) is configured to mechanically andacoustically couple waveguide (1092) with horn (956) of transducerassembly (940). As will be described in greater detail below, guide post(1099) is configured to interact with cam surfaces (1212, 1214, 1216,1218, 1220, 1222, 1242, 1244, 1246, 1248) of waveguide guiding member(1200) to guide and thereby orient waveguide (1092) at an appropriateangular orientation as waveguide (1092) is inserted through body (1202).

Referring back to FIGS. 94-95, knob assembly (1010) of the presentexample comprises a pair of housings (1012) and a lid (1014), which ispivotably coupled with housings (1012). Housings (1012) are securedtogether and thereby encompass a proximal portion of shaft assembly(1050) and a cleaning port body (1300), which will be described ingreater detail below. Housings (1012) also define recesses (1018) thatare configured to receive a pin (1240). As shown in FIGS. 94-95, a pin(1240) is incorporated into shaft assembly (1050) in order to couplecomponents of shaft assembly (1050) that rotate together concomitantly.In particular, pin (1240) is secured within opening (1270) of waveguideguiding member (1200), a corresponding lateral opening (not shown) ofproximal mounting portion (2010) of inner tube (1070), opening (2008) ofproximal mounting portion (2000) of outer tube (1052), and recesses(1018) of housings (1012). Pin (1240) does not contact waveguide (1092)at all.

Pin (1240), opening (1270), the corresponding lateral opening ofproximal mounting portion (2010), and the combination of recesses (1018)all have a circular cross-section, such that pin (1240) provideslongitudinal fixation between waveguide guiding member (1200), innertube (1070), and housings (1012). However, opening (2008) is elongate,such that pin (1240) does not prevent outer tube (1052) from translatinglongitudinally relative to the components that are longitudinally fixedtogether by pin (1240). Nevertheless, pin (1240) provides concomitantrotation of waveguide guiding member (1200), inner tube (1070), outertube (1052), and knob assembly (1010). Waveguide (1092) will rotateconcomitantly with these components due to post (199) being engaged withwaveguide guiding member (1200) as described below; and due to pin(1094) being engaged with arms (2012) as described above. An operatormay thus grasp and rotate knob assembly (1010) relative to housings(1006) to thereby rotate shaft assembly (1050) and end effector (1080)relative to housings (1006).

3. Exemplary Cleaning Mode of Disposable Assembly

As noted above, it may be desirable to clean disposable assembly (1000)from time to time, particularly in interior portions of shaft assembly(1050). As part of this process, it may be desirable to remove waveguide(1092) from disposable assembly (1000). Removal of waveguide (1092) mayfacilitate cleaning of waveguide (1092) and cleaning of the interior ofinner tube (1070). FIGS. 109-114 depict disposable assembly (1000) in acleaning mode that includes removal of waveguide (1092). As shown, whendisposable assembly (1000) is in the cleaning mode, lid (1014) is in anopen position, flange portion (1174) is disengaged from latch (1009)such that inner tube coupling member assembly (1150) is in a proximalposition, and waveguide (1092) is removed from shaft assembly (1052). Itshould be understood that an operator may wish to transition disposableassembly (1000) to the cleaning mode after instrument (800) has beenused in a surgical procedure. It should also be understood that, beforetransitioning disposable assembly (1000) to the cleaning mode, theoperator may first decouple waveguide (1092) from transducer assembly(940) as taught above; then decouple disposable assembly (1000) fromreusable assembly (900).

By way of example, the operator may simply lift lid (1014) manually inorder to place lid (1014) in the open position. The operator may need tosimply overcome friction that is otherwise holding lid (1014) in theclosed position. Alternatively, features of instrument (800) mayautomatically open lid (1014), such as when the operator decouplesdisposable assembly (1000) from reusable assembly (900). The operatormay also manually lift latch (1009) to deform latch (1009) and therebyrelease flange portion (1174) from latch (1009). Alternatively, featuresof instrument (800) may automatically disengage flange portion (1174)from latch (1009), such as when the operator decouples disposableassembly (1000) from reusable assembly (900). Various suitable ways inwhich lid (1014) may be opened automatically, as well as varioussuitable ways in which flange portion (1174) may be disengaged fromlatch (1009) automatically, will be apparent to those of ordinary skillin the art in view of the teachings herein.

As best seen in FIG. 113, when flange portion (1174) is disengaged fromlatch (1009), and inner tube coupling member assembly (1150) is moved tothe proximal position, ridges (1182) of deflector member (1180) bearagainst arms (2012) of proximal mounting portion (2010) of inner tube(1070), thereby deflecting arms (2012) outwardly. This outwarddeflection of arms (2012) disengages arms (2012) from pin (1094) ofwaveguide (1092), allowing waveguide (1092) to be withdrawn proximallyfrom inner tube (1070). It should therefore be understood that ridges(1182) of deflector member (1180) operate similar to tabs (145) of modedrive member (141) against arms (181) as described above. In someversions, a separate instrument may be coupled with waveguide (1092) tofacilitate removal of waveguide (1092) from inner tube (1070) afterinner tube coupling member assembly (1150) has been moved to theproximal position. For instance, a waveguide removal instrument mayinclude a handle with a shaft that is sized to fit within the inner boreof inner tube coupling member assembly (1150). The shaft of thewaveguide removal instrument may have a threaded feature that may bethreaded onto stud (1096) of waveguide (1092) to couple the waveguideremoval instrument with waveguide (1092). Other suitable ways in whichwaveguide (1092) may be removed from shaft assembly (1050) will beapparent to those of ordinary skill in the art in view of the teachingsherein. It should also be understood that the interior of inner tube(1070) may be cleaned in any suitable fashion after waveguide (1092) hasbeen removed.

As shown in FIGS. 113-114, cleaning port body (1300) is disposed withinproximal mounting portion (2000) of outer tube (1052). Cleaning portbody (1300) comprises an elastomeric material (e.g., silicone, etc.) inthe present example. As best seen in FIGS. 115-116, cleaning port body(1300) includes a longitudinally extending portion (1310) and atransversely extending portion (1320). Transversely extending portion(1320) extends through lateral opening (2002) of proximal mountingportion (2000) and defines a port opening (1322). Lid (1014) includes astopper (1016) that is configured to fit in port opening (1322) when lid(1014) is in a closed position (as shown in FIG. 94) and thereby providea fluid and air tight seal of port opening (1322). However, when lid(1014) is in an open position (as shown in FIGS. 109-114), stopper(1016) is fully disengaged from port opening (1322).

Longitudinally extending portion (1310) of port body (1300) includes adistal sealing flange (1312) and defines a lower lumen region (1314) andan upper lumen region (1316). As best seen in FIG. 114, distal sealingflange (1312) is sized and configured to provide a fluid and air tightseal against the inner surface of proximal mounting portion (2000) ofouter tube (1052). The proximal end of lower lumen region (1314) issized and configured to provide a fluid and air tight seal against theouter surface of the distal portion of proximal mounting portion (2010)of inner tube (1070) when inner tube (1070) is fully inserted in lowerlumen region (1314). The portion of lower lumen region (1314) that iscoincident with upper lumen region (1316) is defined by a radius ofcurvature that is less than the radius of curvature defining upper lumenregion (1316). When inner tube (1070) is inserted through lower lumenregion (1314), upper lumen region (1316) remains open to communicatewith port opening (1322) and a gap (1071) that is defined between theouter diameter of inner tube (1070) and the inner diameter of outer tube(1052). In other words, port opening (1322) and upper lumen region(1316) together provide a path for communication of fluid to the gap(1071) that is defined between the outer diameter of inner tube (1070)and the inner diameter of outer tube (1052). An operator may thus coupleport opening (1322) with a source of cleaning fluid as described abovewith respect to ports (153, 155).

However, it should also be understood that when lid (1014) is in aclosed position, and when waveguide (1092) is disposed in inner tube(1070), the fluid and air tight seal provided by stopper (1016) againstport opening (1322), the fluid and air tight seal provided by sealingflange (1312) against the inner diameter of the inner surface ofproximal mounting portion (2000), the fluid and air tight seal providedby the proximal end of lower lumen region (1314) against the outersurface of the distal portion of proximal mounting portion (2010), andthe fluid tight seal provided by fenders (1093) against the innersurface of inner tube (1070) will all provide a proximal seal for shaftassembly (1050). In other words, fenders (1093), port body (1300), andstopper (1016) will together permit shaft assembly (1050) to be insertedinto an insufflated body cavity (e.g., an insufflated abdomen) withoutfear of losing insufflation pressure through interior features of shaftassembly (1050).

4. Exemplary Waveguide Guiding Feature of Disposable Assembly

As described above, an operator may remove waveguide (1092) from shaftassembly (1050) to place disposable portion (1000) in a cleaning mode.After disposable portion (1000) has been suitably cleaned and disposableportion (1000) is otherwise ready for re-use, it may be desirable tore-insert waveguide (1092) into shaft assembly (1050) to preparedisposable portion (1000) for another use in a surgical procedure. Thismay be done with a waveguide (1092) that had been previously used andthen cleaned; or with a new waveguide (1092). In either case, it may bedesirable to ensure that waveguide (1092) is ultimately positioned at aparticular, predetermined angular orientation before disposable portion(1000) is used again. This may be desirable in settings where blade(1090) has a non-circular cross-section. In such settings, the effectson tissue when clamp arm (1082) compresses tissue against anultrasonically activated blade (1090) may vary based on the geometricconfiguration of the region of blade (1090) that is facing arm. Thus,providing predictability and consistency in the angular orientation ofblade (1090) may provide predictable and consistent performance of endeffector (1080). Providing consistency in the angular orientation ofblade (1090) will also provide consistent angular alignment of pin(1094) with arms (2012) when blade (1090) reaches a fully insertedposition.

FIGS. 117A-118F show how waveguide guiding member (1200) willconsistently guide waveguide (1092) into a specific, predeterminedangular orientation when waveguide (1092) is fully inserted intowaveguide guiding member (1200), regardless of the angular orientationat which waveguide (1092) is initially inserted into waveguide guidingmember (1200). Before waveguide (1092) is inserted into waveguideguiding member (1200) as described below, the operator can push innertube coupling member assembly (1150) from the proximal position shown inFIG. 113 to the distal position shown in FIG. 94, with latch (1009)re-engaging flange (1174). This will disengage ridges (1182) ofdeflector member (1180) from arms (2012), enabling arms (2012) toresiliently to resiliently return to the position shown in FIGS. 94 and102. With inner tube coupling member assembly (1150) in the distalposition and arms (2012) returned to the shown in FIGS. 94 and 102, arms(2012) will again reach over ridges (1182) of deflector member (1180) toengage pin (1094) of waveguide (1092) when waveguide (1092) is fullyinserted into waveguide guiding member (1200) as described below.Alternatively, waveguide (1092) and inner tube coupling member assembly(1150) can be simultaneously inserted into waveguide guiding member(1200). As waveguide (1092) and inner tube coupling member assembly(1150) are simultaneously inserted into waveguide guiding member (1200),ridges (1182) of deflector member (1180) will disengage from arms(2012), enabling arms (2012) to resiliently return to the position shownin FIGS. 94 and 102.

FIG. 117A shows waveguide (1092) being initially inserted into waveguideguiding member (1200) at an orientation where post (1099) is angularlymisaligned by approximately 45° clockwise (viewing distally fromthreaded stud (1096)). As the operator inserts waveguide (1092) furtherdistally as shown in FIG. 117B, post (1099) first engages cam surface(1214), passing cam surface (1212) without engaging cam surface (1212).If waveguide (1092) were initially misaligned to a greater angleclockwise, post (1099) would have engaged cam surface (1212) first. Asthe operator inserts waveguide further distally (1092) as shown in FIG.117C, post (1099) engages cam surface (1216). Due to the helicalorientation of cam surface (1216), cam surface (1216) acts against post(1099) to rotate waveguide (1092) counterclockwise. Thiscounterclockwise rotation continues as waveguide (1092) is insertedfurther distally as shown in FIG. 117D, until post (1099) eventuallyencounters the gap defined between cam surfaces (1218, 1244). Aswaveguide (1092) is inserted further distally as shown in FIG. 117E, camsurfaces (1218, 1244) cooperate to guide waveguide (1092) through acertain range of longitudinal motion without rotating waveguide (1092).Post (1099) eventually encounters cam surface (1246), as shown in FIG.117F. At this point, the complementary helical orientations of guidesurfaces (1220, 1246) cooperate against post (1099) to guide waveguide(1092) distally while rotating waveguide (1092) clockwise as waveguide(1092) is inserted further distally as shown in FIG. 117G. Post (1099)eventually encounters cam surface (1222) as shown in FIG. 117H. Aswaveguide (1092) is inserted further distally as shown in FIG. 117I, camsurfaces (1222, 1248) cooperate against post (1099) to guide waveguide(1092) without rotating waveguide (1092) until post (1099) nears endsurface (1260). In the present example, post (1099) does not actuallycontact end surface (1260) or cam surfaces (1222, 1248) when waveguide(1092) is fully disposed in waveguide guiding member (1200). Instead,engagement between pin (1094) and arms (2012) of inner tube couplingmember assembly (1150) arrests longitudinal advancement of waveguide(1092) and maintains the position of waveguide (1092) relative towaveguide guiding member (1200) such that post (1099) is slightly spacedaway from end surface (1260) and cam surfaces (1222, 1248).

At the stage shown in FIG. 117I, waveguide (1092) is fully inserted,with end cam surfaces (1222, 1248) and post (1099) cooperating toprovide waveguide (1092) at a proper angular and longitudinal positionwithin waveguide guiding member (1200). Since waveguide guiding member(1200) is already rotationally and longitudinally fixed within shaftassembly (1050) via pin (1240), waveguide (1092) will be at a properangular and longitudinal position within shaft assembly (1050) uponreaching the position shown in FIG. 117I. It should be noted that, inthe present example, pin (1094) of waveguide (1092) is positionedadjacent to cam surface (1214) and the proximal portion of cam surface(1244) when waveguide (1092) reaches full insertion in waveguide guidingmember (1200). In other words, cam surfaces (1214, 1244) are positionedto accommodate pin (1094) waveguide (1092) reaches full insertion inwaveguide guiding member (1200). In addition, waveguide (1092) ispositioned longitudinally via pin (1094) engaging with arms (2012) ofinner tube coupling member assembly (1150).

FIG. 118A shows waveguide (1092) being initially inserted into waveguideguiding member (1200) at an orientation where post (1099) is angularlymisaligned by approximately 45° counterclockwise (viewing distally fromthreaded stud (1096)). As the operator inserts waveguide furtherdistally (1092) as shown in FIG. 118B, post (1099) first engages camsurface (1242). Due to the helical orientation of cam surface (1242),cam surface (1242) acts against post (1099) to rotate waveguide (1092)clockwise until post (1099) reaches cam surface (1244) as shown in FIG.118C. As the operator inserts waveguide (1092) further distally, camsurfaces (1218, 1244) cooperate to guide waveguide (1092) through acertain range of longitudinal motion without rotating waveguide (1092).Post (1099) eventually encounters cam surface (1246), as shown in FIG.118D. At this point, the complementary helical orientations of guidesurfaces (1220, 1246) cooperate against post (1099) to guide waveguide(1092) distally while rotating waveguide (1092) clockwise until post(1099) encounters cam surface (1222) as shown in FIG. 118E. As waveguide(1092) is inserted further distally as shown in FIG. 118F, cam surfaces(1222, 1248) cooperate against post (1099) to guide waveguide (1092)without rotating waveguide (1092) until post (1099) nears end surface(1260). At this stage, waveguide (1092) is fully inserted. Again, post(1099) does not actually contact end surface (1260) or cam surfaces(1222, 1248) when waveguide (1092) is fully disposed in waveguideguiding member (1200). Instead, engagement between pin (1094) and arms(2012) of inner tube coupling member assembly (1150) arrestslongitudinal advancement of waveguide (1092) and maintains the positionof waveguide (1092) relative to waveguide guiding member (1200) suchthat post (1099) is slightly spaced away from end surface (1260) and camsurfaces (1222, 1248).

It should be understood that, regardless of the angle at which waveguide(1092) is misaligned when waveguide (1092) is being initially insertedinto waveguide guiding member (1200), cam surfaces (1212, 1214, 1216,1218, 1220, 1222, 1242, 1244, 1246, 1248) will cooperate to guide andthereby orient waveguide (1092) at an appropriate angular orientation aswaveguide (1092) is fully inserted through body (1202). Theconfiguration of point (1250) will deflect post (1099) to either camsurface (1212) or cam surface (1242) in the event that waveguide is(1092) initially inserted into waveguide guiding member (1200) at amisalignment angle of 180°.

After the components of shaft assembly (1050) have been cleaned asdescribed above, inner tube coupling member assembly (1150) has beenpushed back to the distal position as described above, and waveguide(1092) has been inserted back into shaft assembly (1050) as describedabove, the operator may then close lid (1014) if the operator has notbeen closed already. At this stage, disposable assembly (1000) may bere-coupled with reusable assembly (900) to re-assemble instrument (800).This re-assembly would include re-coupling of threaded stud (1096) ofwaveguide (1092) with horn (956) of transducer assembly (940) asdescribed above. Re-assembled instrument (800) may then be used in asurgical procedure as described above.

VIII. Exemplary Combinations

The following examples relate to various non-exhaustive ways in whichthe teachings herein may be combined or applied. It should be understoodthat the following examples are not intended to restrict the coverage ofany claims that may be presented at any time in this application or insubsequent filings of this application. No disclaimer is intended. Thefollowing examples are being provided for nothing more than merelyillustrative purposes. It is contemplated that the various teachingsherein may be arranged and applied in numerous other ways. It is alsocontemplated that some variations may omit certain features referred toin the below examples. Therefore, none of the aspects or featuresreferred to below should be deemed critical unless otherwise explicitlyindicated as such at a later date by the inventors or by a successor ininterest to the inventors. If any claims are presented in thisapplication or in subsequent filings related to this application thatinclude additional features beyond those referred to below, thoseadditional features shall not be presumed to have been added for anyreason relating to patentability.

Example 1

An instrument comprising: (a) a body; (b) a shaft assembly extendingdistally from the body, wherein the shaft assembly defines alongitudinal axis; (c) a waveguide guiding member coaxially aligned withthe longitudinal axis, wherein the waveguide guiding member has aplurality of cam surfaces; and (d) an ultrasonic waveguide, wherein theultrasonic waveguide comprises an outwardly extending post, wherein theultrasonic waveguide is insertable into the waveguide guiding memberalong the longitudinal axis, wherein the cam surfaces of the waveguideguiding member are configured to bear against the post to angularlyorient the waveguide about the longitudinal axis.

Example 2

The instrument of Example 1, wherein the post extends outwardly from thewaveguide at only one angular position about a circumference of thewaveguide.

Example 3

The instrument of any one or more of Examples 1 through 2, wherein thewaveguide further comprises a pin, wherein the pin extends outwardlyfrom the waveguide at two opposing angular positions about acircumference of the waveguide.

Example 4

The instrument of Example 3, wherein the pin is proximal to the post.

Example 5

The instrument of any one or more of Examples 3 through 4, wherein thepin is located at a position along the length of the waveguidecorresponding to a node associated with ultrasonic vibrationscommunicated through the waveguide.

Example 6

The instrument of any one or more of Examples 1 through 5, wherein atleast one of the cam surfaces extends along a helically oriented path.

Example 7

The instrument of Example 6, wherein a first cam surface of theplurality of cam surfaces extends along a helical path at a firstorientation, wherein a second cam surface of the plurality of camsurfaces extends along a helical path at a second orientation.

Example 8

The instrument of any one or more of Examples 1 through 7, wherein atleast one of the cam surfaces extends along a path that is parallel tothe longitudinal axis.

Example 9

The instrument of any one or more of Examples 1 through 8, wherein theshaft assembly comprises an inner tube and an outer tube, wherein thewaveguide guiding member is coaxially disposed within a proximal portionof the inner tube.

Example 10

The instrument of Example 9, wherein the inner tube is longitudinallysecured relative to the body.

Example 11

The instrument of Example 10, wherein the outer tube is operable totranslate relative to the body and relative to the inner tube.

Example 12

The instrument of Example 11, further comprising a clamp arm, wherein afirst portion of the clamp arm is pivotably coupled with the inner tube,wherein a second portion of the clamp arm is pivotably coupled with theouter tube, wherein the clamp arm is configured to pivot toward and awayfrom the longitudinal axis in response to longitudinal motion of theouter tube along the longitudinal axis.

Example 13

The instrument of Example 9, wherein the inner tube, the outer tube, thewaveguide guiding member, and the waveguide are all rotatable togetherrelative to the body.

Example 14

The instrument of any one or more of Examples 1 through 13, furthercomprising a grip assembly, wherein the body is configured to removablycouple with the grip assembly.

Example 15

The instrument of Example 14, wherein the grip assembly comprises anultrasonic transducer, wherein the ultrasonic transducer is configuredto couple with the waveguide.

Example 16

An apparatus, comprising: (a) a body; (b) a shaft assembly configured tocouple with the body such that the shaft assembly extends distallyrelative to the body, wherein the shaft assembly comprises: (i) atubular member, (ii) an acoustic waveguide, wherein the acousticwaveguide is operable to selectively couple with an ultrasonictransducer assembly, wherein the tubular member is configured toinsertingly receive the acoustic waveguide, wherein the acousticwaveguide comprises a guide feature, and (iii) a guiding member, whereinthe guiding member is configured to engage the guide feature of theacoustic waveguide and thereby orient the acoustic waveguide in relationto the tubular member.

Example 17

The apparatus of Example 16, wherein the tubular member defines alongitudinal axis, wherein the acoustic waveguide defines a longitudinalaxis, wherein the acoustic waveguide is configured to fit in the tubularmember such that the longitudinal axes are coaxially aligned with eachother.

Example 18

The apparatus of any one or more of Examples 16 through 17, wherein thetubular member defines a longitudinal axis, wherein the guiding memberis configured to engage the guide feature of the acoustic waveguide andthereby orient the acoustic waveguide about the longitudinal axis inrelation to the tubular member.

Example 19

The apparatus of Example 18, wherein the guiding member comprises afirst guide surface, wherein the first guide surface is configured toengage the guide feature of the acoustic waveguide and thereby orientthe acoustic waveguide about the longitudinal axis in relation to thetubular member by rotating the acoustic waveguide in a first directionabout the longitudinal axis in response to advancement of the acousticwaveguide along the longitudinal axis.

Example 20

The apparatus of Example 19, wherein the guiding member furthercomprises a second guide surface, wherein the second guide surface isconfigured to engage the guide feature of the acoustic waveguide andthereby orient the acoustic waveguide about the longitudinal axis inrelation to the tubular member by rotating the acoustic waveguide in asecond direction about the longitudinal axis in response to advancementof the acoustic waveguide along the longitudinal axis.

Example 21

The apparatus of Example 20, wherein the first and second guide surfacesconverge together at a point.

Example 22

The apparatus of Example 21, wherein the guiding member has a proximalend and a distal end, wherein the point is located at the proximal end.

Example 23

The apparatus of any one or more of Examples 19 through 22, wherein thesecond guide surface is distal to the first guide surface.

Example 24

The apparatus of any one or more of Examples 16 through 23, wherein thetubular member defines a longitudinal axis, wherein the guiding membercomprises a pair of longitudinally extending cam surfaces, wherein thelongitudinally extending cam surfaces are configured to engage the guidefeature of the acoustic waveguide and thereby maintain an angularorientation of the acoustic waveguide as the acoustic waveguide isinserted along the longitudinal axis.

Example 25

The apparatus of Example 24, wherein the guiding member has a proximalend and a distal end, wherein the longitudinally extending cam surfacesconverge at the distal end.

Example 26

The apparatus of any one or more of Examples 16 through 25, wherein thetubular member defines a longitudinal axis, wherein the guiding memberdefines a guide channel, wherein the engage the guide feature of theacoustic waveguide is configured to traverse the guide channel as theacoustic waveguide is inserted along the longitudinal axis.

Example 27

The apparatus of Example 26, wherein the guide channel is configured torotate the acoustic waveguide in a first direction as the acousticwaveguide is inserted along the longitudinal axis through a first rangeof longitudinal motion.

Example 28

The apparatus of Example 27, wherein the guide channel is configured torotate the acoustic waveguide in a second direction as the acousticwaveguide is inserted along the longitudinal axis through a second rangeof longitudinal motion.

Example 29

The apparatus of any one or more of Examples 16 through 28, wherein theshaft assembly further comprises a fluid port, wherein the fluid port isconfigured to provide communication of fluid along at least a portion ofthe length of the shaft assembly.

Example 30

The apparatus of Example 29, wherein the fluid port is located distal tothe guiding member.

Example 31

The apparatus of any one or more of Examples 16 through 30, wherein theguide feature of the acoustic waveguide comprises a post extendingtransversely relative to a longitudinal axis of the acoustic waveguide.

Example 32

The apparatus of any one or more of Examples 16 through 31, wherein theguiding member is fixedly secured relative to the tubular member.

Example 33

The apparatus of any one or more of Examples 16 through 32, wherein theshaft assembly further comprises: (i) an ultrasonic blade located at adistal end of the acoustic waveguide, and (ii) a clamp arm pivotablycoupled with the tubular member, wherein the clamp arm is operable topivot toward and away from the ultrasonic blade.

Example 34

An apparatus, comprising: (a) a body; (b) a shaft assembly configured tocouple with the body such that the shaft assembly extends distallyrelative to the body, wherein the shaft assembly comprises: (i) atubular member, wherein the tubular member defines a longitudinal axis,(ii) an acoustic waveguide, wherein the acoustic waveguide is sized forinsertion into the tubular member along the longitudinal axis, and (iii)a guiding member, wherein the guiding member is configured rotate theacoustic waveguide and thereby orient the acoustic waveguide in relationto the tubular member in response to insertion of the acoustic waveguideinto the tubular member along the longitudinal axis.

Example 35

A method of assembling a surgical instrument, the method comprising: (a)positioning a distal end of an acoustic waveguide proximal to a proximalend of a tubular member, wherein the tubular member defines alongitudinal axis; (b) inserting the distal end of the acousticwaveguide into the proximal end of the tubular member; (c) advancing theacoustic waveguide through a first range of motion into the tubularmember and along the longitudinal axis; (d) engaging a first cam surfacewith the acoustic waveguide while advancing the acoustic waveguidethrough the first range of motion, wherein the first cam surface causesthe acoustic waveguide to rotate in a first direction as the acousticwaveguide is advanced through the first range of motion; (e) advancingthe acoustic waveguide through a second range of motion into the tubularmember and along the longitudinal axis; and (f) engaging a second camsurface with the acoustic waveguide while advancing the acousticwaveguide through the second range of motion, wherein the second camsurface causes the acoustic waveguide to rotate in a second direction asthe acoustic waveguide is advanced through the second range of motion.

IX. Miscellaneous

It should be understood from the foregoing that each instrument (10,300) permits a disposable assembly (100, 400) to be removably coupledwith a reusable assembly (200, 500). As noted above, it may be desirableto decouple a disposable assembly (100, 400) from a reusable assembly(200, 500) in order to clean disposable assembly (100, 400) andre-couple disposable assembly (100, 400) with reusable assembly (200,500); or in order to replace a used disposable assembly (100, 400) witha new disposable assembly (100, 400). It should also be understood thatreusable assemblies (200, 500) may be coupled with different kinds ofdisposable assemblies (100, 400). For instance, an operator may bepresented with a selection of disposable assemblies (100, 400) havingvarious lengths of shaft assemblies (150, 450), such that the operatormay choose a disposable assembly (100, 400) having a shaft assembly(150, 450) length that is particularly suited for the task at hand. Asanother merely illustrative example, an operator may be presented with aselection of disposable assemblies (100, 400) having various kinds ofend effectors (180, 480) (e.g., those with and without clamp arms (182),those with different configurations of blades (190), etc.). The operatormay thus choose a disposable assembly (100, 400) having an end effector(180, 480) that is particularly suited for the task at hand. Varioussuitable ways in which operators may be provided with kits and othervehicles for modularity of disposable assemblies (100, 400) will beapparent to those of ordinary skill in the art in view of the teachingsherein.

It should be understood that any of the versions of instrumentsdescribed herein may include various other features in addition to or inlieu of those described above. By way of example only, in addition tothe teachings above, it should be understood that at least part ofinstrument (10, 300) may be constructed and operable in accordance withat least some of the teachings of U.S. Pat. Nos. 5,322,055; 5,873,873;5,980,510; 6,325,811; 6,773,444; 6,783,524; 9,095,367; U.S. Pub. No.2006/0079874; U.S. Pub. No. 2007/0191713; U.S. Pub. No. 2007/0282333;U.S. Pub. No. 2008/0200940; U.S. Pub. No. 2009/0105750; U.S. Pub. No.2010/0069940; U.S. Pub. No. 2011/0015660; U.S. Pub. No. 2012/0112687;U.S. Pub. No. 2012/0116265; U.S. Pub. No. 2014/0005701; U.S. Pub. No.2015/0080924; and/or U.S. Pat. App. No. 61/410,603. The disclosures ofeach of the foregoing patents, publications, and applications areincorporated by reference herein. It should also be understood thatinstrument (10, 300) may have various structural and functionalsimilarities with the HARMONIC ACE® Ultrasonic Shears, the HARMONICWAVE® Ultrasonic Shears, the HARMONIC FOCUS® Ultrasonic Shears, and/orthe HARMONIC SYNERGY® Ultrasonic Blades. Furthermore, instrument (10)may have various structural and functional similarities with the devicestaught in any of the other references that are cited and incorporated byreference herein.

To the extent that there is some degree of overlap between the teachingsof the references cited herein, the HARMONIC ACE® Ultrasonic Shears, theHARMONIC WAVE® Ultrasonic Shears, the HARMONIC FOCUS® Ultrasonic Shears,and/or the HARMONIC SYNERGY® Ultrasonic Blades, and the teachings hereinrelating to instrument (10, 300), there is no intent for any of thedescription herein to be presumed as admitted prior art. Severalteachings herein will in fact go beyond the scope of the teachings ofthe references cited herein and the HARMONIC ACE® Ultrasonic Shears, theHARMONIC WAVE® Ultrasonic Shears, the HARMONIC FOCUS® Ultrasonic Shears,and the HARMONIC SYNERGY® Ultrasonic Blades.

It should be appreciated that any patent, publication, or otherdisclosure material, in whole or in part, that is said to beincorporated by reference herein is incorporated herein only to theextent that the incorporated material does not conflict with existingdefinitions, statements, or other disclosure material set forth in thisdisclosure. As such, and to the extent necessary, the disclosure asexplicitly set forth herein supersedes any conflicting materialincorporated herein by reference. Any material, or portion thereof, thatis said to be incorporated by reference herein, but which conflicts withexisting definitions, statements, or other disclosure material set forthherein will only be incorporated to the extent that no conflict arisesbetween that incorporated material and the existing disclosure material.

Versions of the devices described above may have application inconventional medical treatments and procedures conducted by a medicalprofessional, as well as application in robotic-assisted medicaltreatments and procedures. By way of example only, various teachingsherein may be readily incorporated into a robotic surgical system suchas the DAVINCI™ system by Intuitive Surgical, Inc., of Sunnyvale, Calif.Similarly, those of ordinary skill in the art will recognize thatvarious teachings herein may be readily combined with various teachingsof U.S. Pat. No. 6,783,524, entitled “Robotic Surgical Tool withUltrasound Cauterizing and Cutting Instrument,” published Aug. 31, 2004,the disclosure of which is incorporated by reference herein.

Versions described above may be designed to be disposed of after asingle use, or they can be designed to be used multiple times. Versionsmay, in either or both cases, be reconditioned for reuse after at leastone use. Reconditioning may include any combination of the steps ofdisassembly of the device, followed by cleaning or replacement ofparticular pieces, and subsequent reassembly. In particular, someversions of the device may be disassembled, and any number of theparticular pieces or parts of the device may be selectively replaced orremoved in any combination. Upon cleaning and/or replacement ofparticular parts, some versions of the device may be reassembled forsubsequent use either at a reconditioning facility, or by a userimmediately prior to a procedure. Those skilled in the art willappreciate that reconditioning of a device may utilize a variety oftechniques for disassembly, cleaning/replacement, and reassembly. Use ofsuch techniques, and the resulting reconditioned device, are all withinthe scope of the present application.

By way of example only, versions described herein may be sterilizedbefore and/or after a procedure. In one sterilization technique, thedevice is placed in a closed and sealed container, such as a plastic orTYVEK bag. The container and device may then be placed in a field ofradiation that can penetrate the container, such as gamma radiation,x-rays, or high-energy electrons. The radiation may kill bacteria on thedevice and in the container. The sterilized device may then be stored inthe sterile container for later use. A device may also be sterilizedusing any other technique known in the art, including but not limited tobeta or gamma radiation, ethylene oxide, or steam.

Having shown and described various embodiments of the present invention,further adaptations of the methods and systems described herein may beaccomplished by appropriate modifications by one of ordinary skill inthe art without departing from the scope of the present invention.Several of such potential modifications have been mentioned, and otherswill be apparent to those skilled in the art. For instance, theexamples, embodiments, geometrics, materials, dimensions, ratios, steps,and the like discussed above are illustrative and are not required.Accordingly, the scope of the present invention should be considered interms of the following claims and is understood not to be limited to thedetails of structure and operation shown and described in thespecification and drawings.

1-20. (canceled)
 21. A surgical instrument, comprising: (a) an endeffector, comprising: (i) an ultrasonic blade, and (ii) a clamp armconfigured to actuate relative to the ultrasonic blade between an openposition and a closed position to grasp tissue; (b) a shaft assemblyextending proximally from the end effector, wherein the shaft assemblycomprises: (i) a waveguide in acoustic communication with the ultrasonicblade, (ii) a first tubular member housing the waveguide, wherein thefirst tubular member comprises a first inner diameter and an outerdiameter, wherein the waveguide and the first inner diameter of thefirst tubular member define a first interior, and (iii) a second tubularmember, wherein the second tubular member comprises a second innerdiameter defining a second interior with the outer diameter of the firsttubular member; and (c) a cleaning port assembly configured totransition between an activation mode and a cleaning mode, wherein thecleaning port assembly is configured to provide fluid communicationbetween an exterior environment and both the first interior and secondinterior in the cleaning mode, wherein the cleaning port assembly isconfigured to inhibit fluid communication between the exteriorenvironment and both the first interior and the second interior in theactivation mode.
 22. The surgical instrument of claim 21, wherein thesecond tubular member houses the first tubular member.
 23. The surgicalinstrument of claim 21, wherein the first interior and the secondinterior, while the cleaning port assembly is in the activation mode,are fluidly isolated from each other.
 24. The surgical instrument ofclaim 23, wherein the shaft assembly comprises a distal seal.
 25. Thesurgical instrument of claim 24, wherein the distal seal is associatedwith the waveguide.
 26. The surgical instrument of claim 25, wherein thedistal seal is configured to inhibit a fluid from escaping the firstinterior in a distal direction while the cleaning port assembly is inthe activation mode.
 27. The surgical instrument of claim 26, whereinthe distal seal is configured to allow the fluid to escape the firstinterior in the distal direction while the cleaning port assembly is inthe cleaning mode.
 28. The surgical instrument of claim 23, wherein theshaft assembly comprises a proximal seal.
 29. The surgical instrument ofclaim 28, wherein the proximal seal is associated with the secondtubular member.
 30. The surgical instrument of claim 29, wherein theproximal seal is configured to inhibit a fluid from escaping the secondinterior in a proximal direction while the cleaning port assembly is inthe activation mode.
 31. The surgical instrument of 30, wherein theproximal seal is configured to allow the fluid to escape the secondinterior in the proximal direction while the cleaning port assembly isin the cleaning mode.
 32. The surgical instrument of claim 21, furthercomprising a body.
 33. The surgical instrument of claim 32, wherein aproximal end of the shaft assembly is configured to selectively couplewith the body.
 34. The surgical instrument of claim 33, wherein the bodycomprises a handle assembly.
 35. The surgical instrument of claim 21,wherein the cleaning port assembly is resiliently biased toward theactivation mode.
 36. The surgical instrument of claim 35, wherein theshaft assembly further comprises a latch configured to inhibit thecleaning port from transitioning into the activation mode afterachieving the cleaning mode.
 37. A surgical instrument, comprising: (a)a shaft assembly comprising (i) an ultrasonic waveguide terminatingdistally into an ultrasonic blade, (ii) a first tubular member housingthe ultrasonic waveguide, wherein the first tubular member comprises afirst inner diameter and an outer diameter, wherein the ultrasonicwaveguide and the first inner diameter of the first tubular memberdefine a first interior, and (iii) a second tubular member, wherein thesecond tubular member and the first tubular member are configured toactuate relative to each other for driving a clamp arm between an openposition and a closed position, wherein the second tubular membercomprises a second inner diameter defining a second interior with theouter diameter of the first tubular member; and (b) a cleaning portassembly configured to provide fluid communication between an exteriorenvironment and both the first interior and second interior.
 38. Thesurgical instrument of claim 37, wherein the shaft assembly furthercomprises a proximal knob housing the cleaning port assembly.
 39. Thesurgical instrument of claim 38, wherein the proximal knob comprises asliding cover configured to selectively expose the cleaning portassembly.
 40. A surgical instrument, comprising: (a) an end effector,(b) a shaft assembly extending proximally from the end effector, whereinthe shaft assembly comprises: (i1) a first tubular member, wherein thefirst tubular member comprises a first inner diameter and an outerdiameter, wherein the first inner diameter defines a first interior, and(iii) a second tubular member, wherein the second tubular membercomprises a second inner diameter defining a second interior with theouter diameter of the first tubular member; and (c) a cleaning portassembly configured to transition between an activation mode and acleaning mode, wherein the cleaning port assembly is configured toprovide fluid communication between an exterior environment and both thefirst interior and second interior in the cleaning mode, wherein thecleaning port assembly is configured to inhibit fluid communicationbetween the exterior environment and both the first interior and thesecond interior in the activation mode.